+ All Categories
Home > Documents > Steam Troubleshooting Guide Rev 3

Steam Troubleshooting Guide Rev 3

Date post: 18-Feb-2018
Category:
Upload: edgar-i-ramirez
View: 242 times
Download: 0 times
Share this document with a friend
24
7/23/2019 Steam Troubleshooting Guide Rev 3 http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 1/24  PURPO  The pur ControT the mate can broa   Insta circu  Stea  Proc inde  Desi overl  Most pr categori sections:  Purp  Stea  Leve  Leve great  Leve syste  App  App  App  App  App  The guid in not re Do not h  Controls 704-644 P.O. Bo Charlott  SE ose of this ace steam rial is also ly be divid lation-Rela itry, etc. -Related I ss-Related endent of, n-Related I ooked, etc. oblems are s, but also se: An intr  System O l 1 Troubles l 2 Trouble er time and/ l 3 Trouble ms, heat tra ndix A: Ste ndix B: Ins ndix C: De ndix D: Th ndix E: Per e is designe uired to su esitate to co Southeast I 5000 7500 , NC 28241 document eating syst elevant to ed into four ed Issues: P sues: Low s Issues: Prob nd unrelate ssues: Desi either inst  briefly add duction to erview: A hooting: Ite shooting: I or resource shooting: It sfer, and p am saturatio ructions for cription of rmocouple anent end- d to be foll cessfully p ntact CSI fo c STEAM ROUBLE s to help d m. The gui ther steam categories: oor Contro team suppl lems whose  to, the hea n based on llation or resses the he guide introductio s that are ems that c equirement ms that re ocess detail n temperatu  testing the trainer blo and IR gun of-circuit st wed progre rform trou r assistance EATING SHOOTIN etermine th e is tailore heating sys race install  pressure, s  root cause ing system. inaccurate a steam rela ther two. n to steam s asily perfo n be perfo s. uire some s. re table  peration of -down disc nstructions. eam temper ssively, sta leshooting. with troubl YSTEM G GUIDE e root caus  for Contr ems. Probl tion, inade eam trap fai is process r  ssumption, ed. This g he guide i ystems med by mai rmed by n-depth kn various ste harge clues.  ture gauge ting with L However, shooting C  of heat-re Trace appli ms with ste uate insula lure, etc. elated; ofte components ide is foc s organized ntenance pe aintenance wledge of m trap styl  source. vel 1, Item SI is happy ntroTrace s age 1 of 2 evision: 3 ate: 7 Oct ated proble cations, but am heating ion, incorre  these prob  that require sed on th  in several rsonnel  personnel steam, Con s. 1. CSI invo  to assist as ystems. 2010 ms in a most of systems ct steam ems are heating ese two distinct ut have roTrace lvement needed.
Transcript
Page 1: Steam Troubleshooting Guide Rev 3

7/23/2019 Steam Troubleshooting Guide Rev 3

http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 1/24

 

PURPO

 

The pur ControTthe matecan broa 

•  Instacircu

•  Stea

•  Proc

inde

•  Desi

overl Most pr categorisections:

•  Purp

•  Stea

• 

Leve

•  Levegreat

• 

Levesyste

•  App

•  App

•  App

•  App

• 

App The guid in not reDo not h Controls704-644P.O. BoCharlott 

SE

ose of thisace steamrial is alsoly be divid 

lation-Relaitry, etc.

-Related I

ss-Relatedendent of,

n-Related I

ooked, etc.

oblems ares, but also

se: An intr 

 System O

l 1 Troubles

l 2 Troubleer time and/

l 3 Troublems, heat tra

ndix A: Ste

ndix B: Ins

ndix C: De

ndix D: Th

ndix E: Per 

e is designeuired to su

esitate to co

Southeast I50007500, NC 28241

documenteating systelevant toed into four

ed Issues: P

sues: Low s

Issues: Probnd unrelate

ssues: Desi

either inst briefly add 

duction to

erview: A

hooting: Ite

shooting:  Ior resource

shooting:  Itsfer, and p

am saturatio

ructions for 

cription of

rmocouple

anent end-

d to be follcessfully p

ntact CSI fo

c

STEAM

ROUBLE

s to help d m. The guither steamcategories:

oor Contro

team suppl

lems whose to, the hea

n based on

llation orresses the

he guide

introductio

s that are

ems that cequirement

ms that reocess detail

n temperatu

 testing the

trainer blo

and IR gun

of-circuit st

wed progrerform trou

r assistance

EATING

SHOOTIN

etermine the is tailore

heating sys

race install

 pressure, s

 root causeing system.

inaccurate a

steam relather two.

n to steam s

asily perfo

n be perfos.

uire somes.

re table

 peration of

-down disc

nstructions.

eam temper 

ssively, staleshooting.with troubl

YSTEM

G GUIDE

e root caus for Contr 

ems. Probl

tion, inade

eam trap fai

is process r  

ssumption,

ed. This ghe guide i

ystems

med by mai

rmed by

n-depth kn

various ste

harge clues.

 

ture gauge

ting with LHowever,shooting C

  of heat-reTrace applims with ste

uate insula

lure, etc.

elated; ofte

components

ide is focs organized 

ntenance pe

aintenance

wledge of

m trap styl

 

source.

vel 1, ItemSI is happyntroTrace s

age 1 of 2

evision: 3

ate: 7 Oct

ated problecations, butam heating

ion, incorre

 these prob

 that require

sed on th  in several

rsonnel

 personnel

steam, Con

s.

1. CSI invo to assist asystems.

2010

ms in amost ofsystems

ct steam

ems are

heating

ese twodistinct

ut have

roTrace

lvementneeded.

Page 2: Steam Troubleshooting Guide Rev 3

7/23/2019 Steam Troubleshooting Guide Rev 3

http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 2/24

 

STEAM

 

In gener 1 for a c 

•  Boil press jacke

•  Steahead head mani

•  Stea

manimanitrap i

•  Heat(jack tubincircuelemcond of eato th

• 

Steasysteallooper singl

•  Conexcestrai

•  Con pipethe b

the cretur trap

SYSTEM

l, a steam hnceptual sk 

r. In the bure is usedting system

  Header.r also servr must be

fold.

Manifold.

fold servesfolds comms located at

ng Circuiteted pipe, bg is used tit. Flexibleent to the nensate fromh heating c jacketing s

  Trap. Thm. The pur ing the cotion of the

e steam trap

ensate Mation that eer and is lo

ensate Heaheader refer oiler so that

ondensate h pressure.tyles have

VERVIE

eating systeetch):

oiler, heat ito control t.

Steam exits as a reser large enou

 Smaller di

as the braonly have 4the bottom

. A typicolt-on jacke  transportmetal hosext within tthe last eleircuit mustystem befor 

  steam traose of thedensate thaeating systor the cond 

ifold. Thch branchated betwe

er. Condered to as thit can be re

eader to avoigh conde

ifferent lev

STEAM

ROUBLE

 

will cons

s added toe temperat

  the boilervoir that feh to mini

ameter pipi

ch point16 branchef the manif 

l heatingting, or tubteam from

are comme circuit.ent in the

e carefullye the steam

is locatedsteam trapt is generam. Two seensate may

condensacontains an two isola

sate fromcondensat

heated into

id creatingsate returnls of tolera

EATING

SHOOTIN

st of the fol

water to gere of the st

through pids steam toize pressu

g connects

or supplyi, and each

old to keep

ircuit is c tracing) w

the steamnly used tre-insulate

circuit to thdesigned anas lost too

 between tis to mainted to escaarate suppluild up ins

e manifold steam trap.ion valves.

ach of theheader. T

steam. Spe

xcessive p pressure ince for high

YSTEM

G GUIDE

lowing maj

nerate steaeam and to

ing referre the individ e drop bet

the steam h

g the indiranch conthe manifol

mprised ohich are coanifold toallow thetubing is

e steam trad analyzedmuch press

e steam ciin the steae. A worki points (cir de one of t

  resemblesThe steam

ondensatee condensaial attentio

essure dropibits stea

condensate

r compone

  at a certamotivate th

  to as theual heating

een the b

eader to a s

idual heatiins an isola clear of co

  a groupnected in s

the first hesteam to flolso used to. The lengo ensure frere.

cuit and thm pressureng steam tr uits) cannoe circuits.

the steamtrap is us

anifolds flte header re must be gi

which lead   trap operatreturn press

age 2 of 2

evision: 3

ate: 7 Oct

ts (referenc

in pressure.e steam thr 

steam head circuits. Tiler and th

eam manif 

g circuits.tion valve.densate.

f heatingeries. Pre-iting elemew from onetransport sth and confish steam is

e condensatin the circap is cruci be combin

manifoldally preced 

ows into aurns liquidven to the d 

 to high coion; differere.

2010

e Figure

Boilerugh the

r. Thee steame steam

ld. The

SteamA steam

lementsnsulatedt in theheatingam and

gurationsupplied

e returnit whilel to thed into a

ith theed by a

ommonwater toesign of

densatet steam

Page 3: Steam Troubleshooting Guide Rev 3

7/23/2019 Steam Troubleshooting Guide Rev 3

http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 3/24

 

igure 1: Sy tem Overvi

STEAM

ROUBLE

ew Diagra

EATING

SHOOTIN

 (numbers

YSTEM

G GUIDE

orrespond to troublesh

age 3 of 2

evision: 3

ate: 7 Oct

oting steps)

 

2010

Page 4: Steam Troubleshooting Guide Rev 3

7/23/2019 Steam Troubleshooting Guide Rev 3

http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 4/24

 

LEVEL

Diagnos• 

1.  Desi

 Descrip

The Coobjectiassump

 Action

LocateContro

Data’ b• 

• 

• 

• 

• 

 Respon

If any oimpact.

 Results

 

1 TROUB

ic Tools RSI ControT

n Conditio

tion

troTrace se. While thions are list

he area of trace install

x match thhe process

he thermal

he steam s

he pipe siz

he insulati

e

f the design

 Notes

ESHOOT

quired: ace installa

ns 

stem desig complete led on the in

e piping thtion drawi

 as-built sy

 objective

 pply press

e

on type and

assumption

STEAM

ROUBLE

NG (Proc

ion drawin

 is based onst of designstallation dr 

t is suspectgs for that

tem. The

re

thickness.

s do not ma

EATING

SHOOTIN

ss Conditi

s

a set of des assumptiowings.

ed to be therea; Verify

ajor assum

ch the actu

YSTEM

G GUIDE

ns and Sys

ign assumpts may not b

source of ththat the ass

tions are:

l system co

em Install

ions and a se readily av

e problem amptions lis

tact CSI fo

age 4 of 2

evision: 3

ate: 7 Oct

tion)

 pecific ther ilable, seve

d obtain thed in the ‘C

 an analysi

 Initi

 

2010

alral key

eT Design

of the

ls / Date

Page 5: Steam Troubleshooting Guide Rev 3

7/23/2019 Steam Troubleshooting Guide Rev 3

http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 5/24

 

 2.  Con

 Descrip

Sometirelated,

 Action

Verify tfollowiAppend 

•  Mi

•  Lea

•  Da

•  Che

•  Opeanti

 Respon

If a proconcer 

 Results

 

irm the Pr

tion

es process but are actu

hat there ar g list givesix D if mak 

ing of diffe

ing valves

aged equip

mical reacti

rating procipated)

e

ess issue iss before inv

 Notes

blem is He

related issually indepe

 no processseveral exang tempera

ent tempera

allowing un

ment (e.g. c

on forming

dures outsi

a likely proestigating t

STEAM

ROUBLE

at Related

s will causdent issues.

related issu ples of proure measur 

ture proces

anted proc

talyst) phy

olids in the

e of the des

 blem sourcee heating s

EATING

SHOOTIN

 plugging,

es that coulcess issuesments):

streams re

ess to enter

ically plug

line (e.g. c

ign conditio

 it may mak stem.

YSTEM

G GUIDE

orrosion, et

 be the souhat can app

ulting in qu

a line

ing the line

rsul, sulcret

ns (e.g. pro

e more sens

c. These ca

ce of the pr ear as heati

enching of t

e)

ess enters t

e to investig

age 5 of 2

evision: 3

ate: 7 Oct

 appear to b

 blem. Theg issues (R 

e hotter str 

e line cold 

ate the proc

 Initi

 

2010

e heat

fer to

eam

r than

ess

ls / Date

Page 6: Steam Troubleshooting Guide Rev 3

7/23/2019 Steam Troubleshooting Guide Rev 3

http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 6/24

 

 3.  Stea

 Descrip

Incorreheat loa

 Action

Verify tCSI. V

•  All

•  All

•  The

•  Onlune

•  Eacmul

 Respon

If any pCSI for

 Results

 

Circuitr

tion

t circuitry cd, and other 

hat the Conrify that:

ump-overs

ump-overs

steam flow

the compo pected co

 circuit hastiple steam

e

ortion of than analysis

 Notes

an result in problems.

roTrace cir 

are looped

are CSI sup

direction is

nents show ponents)

a single suraps, but no

 circuitry diof the impa

STEAM

ROUBLE

condensate

uits are rou

own

lied compo

as indicated 

 on the inst

 ply and a sit visa-versa

ffers from tt.

EATING

SHOOTIN

 back-up, ex

ted accordi

nents

on the dra

llation dra

ngle steam

e installati

YSTEM

G GUIDE

essive stea

g to the ins

ings

ing are inc

rap (note th

n drawings

 pressure d 

allation dra

uded in the

at a single s

, correct the

age 6 of 2

evision: 3

ate: 7 Oct

rop, excessi

ings provi

 circuit (no

 pply can fe

circuitry or

 Initi

 

2010

ve steam

ed by

ed

contact

ls / Date

Page 7: Steam Troubleshooting Guide Rev 3

7/23/2019 Steam Troubleshooting Guide Rev 3

http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 7/24

 

 4.  Unh

 Descrip

In geneconditirequire

 Action

Check tmight r shoes c

•  In-l

•  Pip

• 

Jac

•  Bra

 Respon

Contact

 Results

 

 5.  Insu

 Descrip

Proper i Action

Verify t

•  Fitti

•  Val

•  Fla

• 

Inst

•  Bra

•  Sup

•  Co

 ResponFully in

 Results

 

ated Com

tion

al, all in-lins, other itheating.

he line for aquire additiuld be pro

ne valves a

 supports

eted compo

ch connect

e

CSI to disc

 Notes

ation Qual

tion

nsulation is

hat the line

ngs

es

ges

umentation

ch Connec

 ports

troHeats

esulate any p

 Notes

onents 

e componems, such a

ny unheated onal heatinlem. The fo

d instrume

nents witho

ons

uss the imp

ty 

critical to t

is fully insu

ions

ortion of th

STEAM

ROUBLE

ts (valves,ranch conn

 in-line co. For exam

llowing list

tation

t a steam s

ct of unhea

e operation

ated includ 

 line that is

EATING

SHOOTIN

ittings, etc)ections, fla

 ponents. Alle, an unhe

contains so

 pply

ed compon

of a Contro

ng all:

found to be

YSTEM

G GUIDE

require heatge pairs, lar 

so check foted trunione generic i

nts.

Trace syste

lacking.

ing. Depenge supports,

 any conspion a line wiems to look 

.

age 7 of 2

evision: 3

ate: 7 Oct

ing on the s etc. may al

uous itemsth several h for:

 Initi

 

 Initi

 

2010

 pecifico

thateated tee

ls / Date

ls / Date

Page 8: Steam Troubleshooting Guide Rev 3

7/23/2019 Steam Troubleshooting Guide Rev 3

http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 8/24

 

6.  Stea

 Descrip

Significsteam l

 Action

Check t

 Respon

Repairlikely a

 Results

 

Leaks 

tion

ant steam leaks are not

he line for s

e

ny signific problem so

 Notes

aks increaslikely to ha

team leaks.

nt steam lerce.

STEAM

ROUBLE

 the steam le a signific

ks; while it

EATING

SHOOTIN

oad of a cir nt impact.

is prudent t

YSTEM

G GUIDE

uit and red 

 repair any

ce the oper 

small stea

age 8 of 2

evision: 3

ate: 7 Oct

ting pressu

 leaks, thes

 Initi

 

2010

e. Small

are not

ls / Date

Page 9: Steam Troubleshooting Guide Rev 3

7/23/2019 Steam Troubleshooting Guide Rev 3

http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 9/24

 

LEVEL

Diagnos• 

•  S

•  S

• 

7.  Strai

 Descrip

A clogg

 Action

Open t properl

 Respon

If the stvalve w

 Results

 

8. 

Stea Descrip

The steend of tis accep

 Action

Measur  before tsteam t by proc

 Respon•  If t

•  If t

 Results

 

2 TROUB

ic Tools RSI ControT

urface ther 

team trap di

eference th

ner Blow-

tion

ed strainer

e blow-dow operating

e

rainer has bill remove t

 Notes

Temperation

m pressurehe circuit istable throu

e the tempehe steam tramperature,

ess instructi

ee temperatu

e temperatu

 Notes

ESHOOT

quired: ace installa

ocouple pr 

agnostic too

 diagram in

own 

ill inhibit c

n valve on tircuit shoul

come cloge contamin

ture (end o

temperatur the worst chout the cir 

ature of the p). The temthough thisons. (Appen

re is accept

re is below

STEAM

ROUBLE

NG (Stea

ion drawin

 be and met

ls (varies b

 the ‘Steam

ondensate r 

he steam trad have a str 

ed with coants and res

 circuit) 

gradually r se location;uit.

steam at therature shoumber will

dix D conta

 ble: skip to

 pecificatio

EATING

SHOOTIN

 System Di

s

er (or IR gu

 trap style)

System Ov

emoval.

 p strainer (ing, clean d 

taminants, itore proper

educes as itif the stea

 end of theuld typicall vary fromns procedu

Level 3 ite

: proceed t

YSTEM

G GUIDE

gnostic)

)

rview’ secti

 equipped)scharge of

t is possibleircuit oper 

 progresses pressure/te

ircuit (eith be no cold rocess to pes for meas

s.

item 9.

on

and observeteam with s

that openintion.

hrough themperature i

r at the laster than 10°ocess. Contring tempe

age 9 of 2

evision: 3

ate: 7 Oct

 the dischar ome conde

 the blow-

 Initi

 

team circui acceptable

CT element below thect CSI forature.)

 Initi

 

2010

e. Asate.

own

ls / Date

. Thehere, it

or justupplyrocess

ls / Date

Page 10: Steam Troubleshooting Guide Rev 3

7/23/2019 Steam Troubleshooting Guide Rev 3

http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 10/24

 

 9.  Stea

 Descrip

If the st pressur 

 Action

Measur shouldsteam t

 Respon

•  If tThecon

•  If tInvsize

 Results

 

10. Sup

 Descrip

In orde/ pipe bspecific

 Action

Measur 

 Respon

•  If t

•  If t

first5°Fcon11.to a

 Results

 

Tempera

tion

eam pressur .

e the tempeorrespond

 ble in App

e

e temperature is eitherensate; pro

e temperatustigate thed, etc.), also

 Notes

ly Tubing 

tion

to minimize used, andations, it is

e the supply

e

e supply tu

e supply tu element of below the sact CSI forf the tempealyze the i

 Notes

ture (suppl

e/temperatu

ature of theith the stea

ndix A).

re is acceptxcessive pr ceed to item

re is belowteam utiliti check item

e the pressuhat the lengossible tha

tubing dia

ing meets t

ing does noControTrac pply steam

 process byrature is lo pact.

STEAM

ROUBLE

 manifold)

e in the cir 

steam at thm supply pr 

 ble at thessure drop10.

 pecificatios (boiler se12.

e drop in thth not excee excess pre

eter and le

e 100ft of

t meet the 1 in the circ

 temperatur rocess instr , replace th

EATING

SHOOTIN

 

uit is low, i

 supply maessure liste

anifold (butn the suppl

 at the man-point appr 

e supply tud 100ft. If tsure drop i

gth.

/4” require

00ft of 3/4”it. The tem, though thi

uctions. If t supply tub

YSTEM

G GUIDE

t may be a r 

ifold in theon the inst

 too cold attubing / ci

fold: The st priate, stea

ing, CSI tye supply tu the supply

ent procee

requiremenerature sho

s number we temperat

ing with 10

esult of low

same mannllation dra

the last elecuit or the

eam supplydistributi

ically speci bing/pipe d tubing may

to item 11

t, measure tuld typicallill vary frore is reasonft of 3/4” t

age 10 of

evision: 3

ate: 7 Oct

steam syste

r. The teming (refere

ent / steamircuit is fill

 pressure isn header pr 

 Initi

 

fies that 3/4es not meet

occur.

.

e temperat be no cold  process toable, procee bing or con

 Initi

 

4

2010

supply

eraturece the

trap):d with

oo low. perly

ls / Date

” tubingthese

re of theer than process;d to item 

tact CSI

ls / Date

Page 11: Steam Troubleshooting Guide Rev 3

7/23/2019 Steam Troubleshooting Guide Rev 3

http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 11/24

 

11. Stea

 Descrip

Steam tsteam udiagnosfor anyadvancgreater

 Action

CSI recoperati

•  Dis

gen

 pur • 

Rep Note th

the ther 

thermo

 Respon

•  The

• 

The

 Results

 

Trap Op

tion

ap failure incontrolled tic methodstype of stead diagnostievel of fam

ommends tn:

onnect theral, the dis

 condensatlace the stet thermosta

mal perfor 

 ynamic ste

e

steam trap

steam trap

 Notes

ration 

a commonor closed (vary from t trap, but r 

 procedureiliarity with

at one of th

team trap f harge shoul

 or live steam trap withtic steam tr 

ance of the

m traps are

s operating

s failed (eit

STEAM

ROUBLE

cause of steompletelyap style toequire that t which dosteam trap

following

om the cond be a mixt

m, the trapa known g ps back up

circuit even

 sensitive to

correctly: P

er open or

EATING

SHOOTIN

am circuit f r partiallyrap style. The trap be d ot require t peration.

ool-proof

ensate reture of flash

hould be cood unit.condensate

if the steam

 condensate

oceed to ite

losed): Re

YSTEM

G GUIDE

ilures. Stealocking thee followin

isconnected e steam tra

ethods be u

n system ateam and c

nsidered fa

into the ste

 trap is ope

 return pres

m 12.

lace the ste

m traps canflow of stea two diagno. Appendix

to be remo

sed to verif 

d observe tndensate. I

lty.

m circuit; t 

ating corre

sure (refere

m trap.

age 11 of

evision: 3

ate: 7 Oct

fail open (pm). Steam tstic method  contains

ved but req 

 proper ste

e discharge the dischar 

is can com

ctly. Note th

ce item 13)

 Initi

 

4

2010

assingap

s workoreire a

m trap

. Inge is

romise

at

ls / Date

Page 12: Steam Troubleshooting Guide Rev 3

7/23/2019 Steam Troubleshooting Guide Rev 3

http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 12/24

 

12. Stea

 Descrip

If the stroutedcondensupply

 Action

Check t

 Respon

•  The

•  The

 Results

 

Supply

tion

eam trap onrom the supate load woanifold we

he operatio

e

steam trap

steam trap

 Notes

anifold Tr

the steam s ply piping iuld create ere to fail op

 of the stea

s operating

s failed (eit

STEAM

ROUBLE

 pply manif to the circucessive pre

en, the leak

trap on th

correctly: P

er open or

EATING

SHOOTIN

old were toits that feed ssure drop icould reduc

 supply ma

oceed to ite

losed): Re

YSTEM

G GUIDE

ail closed,from the lo the circuit

e the supply

ifold.

m 13.

lace the ste

xcessive coer manifol

. If the stea pressure.

m trap.

age 12 of

evision: 3

ate: 7 Oct

ndensate wd taps. The

trap on th

 Initi

 

4

2010

uld beexcessivesteam

ls / Date

Page 13: Steam Troubleshooting Guide Rev 3

7/23/2019 Steam Troubleshooting Guide Rev 3

http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 13/24

 

13. Stea

 Descrip

The ratacross tcondenhigh, th

 Action

Measur load at

• 

• 

• 

• 

Alternaoperati

 Respon

• 

TheLev

• 

Thetheone

 Results

 

Trap Siz

tion

at which ae trap. If tate at the rae trap may

e the condehe measure

he differeressure dro

supply presressure)

typical Che condenondensate

and Appe

hermodynively, discon is restore

e

steam trapel 3 items.

condensateteam utiliticapable of

 Notes

 / Condens

steam trap ce condensatte it is beinot be able t

sate returndifferentia

tial pressur  p (usually aure – 10psi

ntroTrace cate return pemperaturendix D)

mic steamnnect the st, the conde

s properly s

return presss or, if theandling the

STEAM

ROUBLE

ate Return

an discharge return pre generateddischarge

ressure anl pressure.

across the bout 10psi) pressure dr 

ircuit steamressure canand looking

raps are espam trap frosate return

ized and the

ure is too hiondensatecondensate

EATING

SHOOTIN

Pressure 

e condensatsure is tooy the circuihe condens

 verify thatote that:

rap is the stminus the c p – 20psi c

 load is lessoften be me up the pres

ecially sens the conde

 pressure is

condensate

gh for the sressure is nreturn press

YSTEM

G GUIDE

is a functiigh, the tra

t. If the conte at all.

the steam tr 

eam supplyndensate rendensate re

than 150 lbsured indir 

sure on a st

tive to highnsate returnoo high.

return pres

eam trap siot too excesure.

n of the dif  will be unensate retu

 p is rated t

 pressure miturn pressur turn pressur 

hr.ectly by meam table. (r 

 condensatesystem; if c

ure is reaso

e / style beisive, replac

age 13 of

evision: 3

ate: 7 Oct

erential pre ble to discn pressure i

 handle the

us the circe. (e.g. 50pe = 20psi di

suring theeference Ap

return presorrect circu

able: Proc

g used: In the steam t

 Initi

 

4

2010

ssurearge thes very

steam

iti steamfferential

 pendix

ures.t

ed to

estigaterap with

ls / Date

Page 14: Steam Troubleshooting Guide Rev 3

7/23/2019 Steam Troubleshooting Guide Rev 3

http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 14/24

 

LEVEL

14. 

Desi Descrip

The Coobjectilisted oreadily

 Action

Contactassump

•  Cop

•  The

• 

The

•  The

•  Pipi

 Respon

•  Co

 Results

 

3 TROUB

n Conditiotion

troTrace se. Each of t the Controvailable to

CSI to coions listed

ies of appli

 process na

 process flo

 process te

ng material,

e

tact CSI for

 Notes

ESHOOT

ns (Advanc

stem is desiese design

Trace instalthe end use

 pare the desn the instal

able P&ID

e

rate

 perature

and schedu

assistance.

STEAM

ROUBLE

NG (CSI I

ed) 

gn is basedassumptionlation drawi.

ign assumpation drawi

 

le

EATING

SHOOTIN

volvement

on a set of d  should bengs, the co

ions to theg, CSI will

YSTEM

G GUIDE

Recomme

esign assuerified. W plete list o

s-built syst likely requi

ded)

 ptions andile a few ba design ass

m. In additire:

age 14 of

evision: 3

ate: 7 Oct

 specific thsic assumptimptions ma

on to the

 Initi

 

4

2010

rmalons arey not be

ls / Date

Page 15: Steam Troubleshooting Guide Rev 3

7/23/2019 Steam Troubleshooting Guide Rev 3

http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 15/24

 

15. Poor

 Descrip

Poorlyflanges,

 Action

Contact

•  Co

the

•  Loofro

•  Pho

 Respon

•  Co

 Results

 

16. Con

 Descrip

Poor qu pipe. T

 Action

In gene

•  Mis

•  Lar co

•  Poo

 Respon

•  Co

 Results

 

ly Heated

tion

eated areassupports, fi

 CSI for hel

 pare the obontroTrac

k for items process to

tograph sus

e

tact CSI for

 Notes

roTrace In

tion

ality installe installati

al, look for:

sing heat tra

e gaps bet pound shou

rly spaced

e

tact CSI for

 Notes

reas 

are difficulttings, etc r 

 p spotting p

served locat installatio

hat may req  process. (e.

ect areas.

assistance.

stallation 

tion will ren quality ca

:

nsfer comp

een the pipld not excee

ontroTrace

assistance.

STEAM

ROUBLE

 to spot oncquire heati

orly heated 

ions of Con drawings.

uire additio. supports,

ult in inaden be difficu

und.

and the Cd 1/8”).

elements (l

EATING

SHOOTIN

e a system ig is depend 

 areas on a

troTrace co

al heating,flanges, ins

uate heat tt to ascertai

ntroTrace e

ngitudinall

YSTEM

G GUIDE

s insulated.ent on the s

 insulated li

nections to

though theruments, br 

ansfer betwn once the s

lements (Th

 or circumf 

Additionallecific proc

ne. As a sta

the expecte

eating requnch connec

een the Conystem is ins

e thickness

erentially).

age 15 of

evision: 3

ate: 7 Oct

, the extentss conditio

ting place:

 locations

irements witions, etc)

 Initi

 

troTrace anlated.

f the heat t

 Initi

 

4

2010

to whichs.

ased on

l vary

ls / Date

the

ansfer

ls / Date

Page 16: Steam Troubleshooting Guide Rev 3

7/23/2019 Steam Troubleshooting Guide Rev 3

http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 16/24

 

17. Bloc

 Descrip

It is rar circuit.

 Action

It maycircuit;suspectforcing

 Respon

•  An

• 

The

 Results

 

age in the

tion

, but possibThis will re

e possible ta sudden dr d the easie

water or air

e

 bstruction

circuit is cl

 Notes

Circuit 

le for foreigult in exces

o locate an p in tempet approach backwards

s present: C

ear: Contact

STEAM

ROUBLE

n material tsive pressur 

 bstructionature/pressay be to at

hrough the

lear the obs

 CSI for ass

EATING

SHOOTIN

 become loe drop throu

y measurinre indicatestempt to clecircuit.

ruction usi

stance.

YSTEM

G GUIDE

dged in thegh the circu

 the steaman obstructr the obstr 

g appropria

supply tubiit.

temperatureon. If an obction witho

te means.

age 16 of

evision: 3

ate: 7 Oct

g or the Co

 pressure alstruction ist locating i

 Initi

 

4

2010

troTrace

ng the

 by

ls / Date

Page 17: Steam Troubleshooting Guide Rev 3

7/23/2019 Steam Troubleshooting Guide Rev 3

http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 17/24

 

APPEN

 

IX A (Sat rated Stea

psig0

5

10

15

20

22

24

26

28

30

32

34

36

38

40

42

44

46

48

50

52

54

5658

60

62

64

66

68

70

72

74

76

7880

85

90

95

100

105

110

115

120

STEAM

ROUBLE

m Table)

°F212.

227.

239.

249.

258.

261.

265.

268.

271.

274.

276.

279.

281.

284.

286.

289.

291.

293.

295.

297.

299.

301.

303.305.

307.

309.

310.

312.

314.

316.

317.

319.

320.

322.323.

327.

331.

334.

337.

341.

344.

347.

350.

EATING

SHOOTIN

  b0 0

1 0

4 0

8 1

8 1

2 1

3 1

3 1

2 1

1 2

8 2

3 2

8 2

4 2

7 2

0 2

2 3

5 3

5 3

7 3

9 3

6 3

6 34 4

4 4

2 4

8 4

6 4

2 4

0 4

7 5

3 5

9 5

3 58 5

6 5

2

6

8

1 7

1 7

2 7

1 8

YSTEM

G GUIDE

rg.0

.3

.7

.0

.4

.5

.7

.8

.9

.1

.2

.3

.5

.6

.8

.9

.0

.2

.3

.4

.6

.7

.9

.0

.1

.3

.4

.5

.7

.8

.0

.1

.2

.4.5

.9

.2

.5

.9

.2

.6

.9

.3

°C100.0

108.4

115.2

121.0

126.0

127.8

129.6

131.3

132.9

134.5

136.0

137.4

138.8

140.2

141.5

142.8

144.0

145.3

146.4

147.6

148.7

149.8

150.9151.9

153.0

154.0

154.9

155.9

156.8

157.0

158.7

159.6

160.5

161.3162.1

164.2

166.2

168.1

169.9

171.7

173.4

175.1

176.7

age 17 of

evision: 3

ate: 7 Oct

4

2010

Page 18: Steam Troubleshooting Guide Rev 3

7/23/2019 Steam Troubleshooting Guide Rev 3

http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 18/24

 

psig125

130135

140

145

150

155

160

165

170

175

180

185

190

195

200

STEAM

ROUBLE

°F352.

355.358.

360.

363.

365.

368.

370.

373.

375.

377.

379.

381.

383.

385.

387.

EATING

SHOOTIN

  b9 8

6 93 9

9 9

4 1

9 1

2 1

6 1

9 1

3 1

4 1

6 1

7 1

7 1

9 1

9 1

YSTEM

G GUIDE

rg.6

.0

.3

.7

.0

.3

.7

1.0

1.4

1.7

.1

.4

.8

.1

.4

.8

°C178.3

179.8181.3

182.7

184.1

185.5

186.8

188.1

189.4

190.7

191.9

193.1

194.3

195.4

196.6

197.7

age 18 of

evision: 3

ate: 7 Oct

4

2010

Page 19: Steam Troubleshooting Guide Rev 3

7/23/2019 Steam Troubleshooting Guide Rev 3

http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 19/24

 

APPEN

 

Diagnoso 

T Inverte

o  Failu 

 

 

Veri 

 

Float an

o  Failu 

 

 

 

Veri 

 

 

IX B (Ste

ic Tools Rechanics st

rap manufa

 Bucket Tr

re modes:PluggedLost priRestore pDamaged or open p

ying normaListen tocontinuodischargeIf trap isthan othe

d Thermos

re modes:Float collDamaged 

or open pAir ventAir ventcontinuodrop in t

ying normaListen todischargethan a pr If a downreturn to

dischargereturns toA failedfrom thevent.

m Trap Di

quired: ethoscope oturer consu

aps

ent: fail col

e: fail hot , crime by clo, worn, or bosition.

operation:trap with ms discharge(characteriailed open t, properly

atic Traps

apsed or pu, worn, or b

osition.lugged or f ailed open:sly dischar e circuit.operation:

trap with m continuous perly workistream valvhe continuo

 its condens steady state pen air venondensate

STEAM

ROUBLE

gnostic)

appropriatltative supp

d  due to inaharacterizeing valve aund mecha

chanics ste(characteristic of normhe dischargorking trap

ctured: fail

und mecha

iled closed:ail hot ; thees live stea

chanics stey. A failedng trap.

is closed f us discharg

ate rapidly.may be dif 

eturn syste

EATING

SHOOTIN

 trap diagnrt

 bility to dis by continuter trap fornism: fail c

hoscope. Ntic of lightl to heavywill be co

s.

cold  due tonism: fail c

  fail cold  d  primary tra

; this may

hoscope (c pen trap’s

r a minutesound righ

nd then sett

icult to det is a fool-p

YSTEM

G GUIDE

stic tool

harge air.ous dischar  few minutld or hot  d 

rmal operateam loads)team loads)tinuous an

inability ofld or hot  d 

e to inabilit mechanisor may not

mpare to k ischarge w

nd then re-t away. A p

le down to

ct by listenroof metho

e with boues and re-ope to trap eit

ion is eitheor an inter .a louder, hi

float to opee to trap eit

y to dischar  is operatioause signifi

own good tll be louder

opened, a faoperly oper 

 slow disch

ng. Discon of detectin

age 19 of

evision: 3

ate: 7 Oct

cing buckeening.er stuck in

a light, quiittent open

gher pitch s

 discharge.er stuck in

e air.nal but the tcant steam

aps). Floatand a highe

iled open tr ating trap w

rge as the t

ecting the t a failed op

4

2010

.

closed

etclose

ound

closed

rapressure

rapsr pitch

 p willill

ap

apen air

Page 20: Steam Troubleshooting Guide Rev 3

7/23/2019 Steam Troubleshooting Guide Rev 3

http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 20/24

 

Thermo

o  Failu 

 

o  Veri 

 

 

Thermo

o  Failu 

 

o  Veri 

 

 

 

ynamic T

re modes:

Trap seatDebris in passagew

ying normaListen toevery 10DischargicondensaDisconnetrap oper operation

tatic Trap

re modes:Damaged or open pDebris in passagew

ying normaIn some cintermitteIf the tra

stop, theClose vallisten to tvolume aThermostconsult

aps

disk worn:trap: fail ho

ay.operation:

trap with mo 30 seconng every 5e back-prescting the tration as the.

, worn, or bosition.trap: fail ho

ay.operation:

ases (typicantly, this in is cooled b

 return to stve after trape dischargd pitch wh

atic traps caanufacturer

STEAM

ROUBLE

ail hot  duet or cold  du

chanics stes. Dischargeconds or lsure, or (3)

 p from the condensate

und mecha

t or cold  du

lly with neaicates a pr  spraying i

ady state.to allow co. If the trapn the disch

n usually befor proper

EATING

SHOOTIN

o inabilitye to debris p

hoscope. Ne durationss is a signn undersiz

ondensate r eturn press

nism: fail c

e to debris p

r-to-steam t perly functi with water

densate tois failed oprge transiti tested by procedure.

YSTEM

G GUIDE

o seal propreventing d 

rmal operaill dependof either (1)d trap.turn systere plays a s

ld or hot  d 

reventing tr 

mperatureoning trap.the dischar 

 build up inn, the discns from coacing them

rly.sc from sea

ion is a perin the circui a worn trap

 is not a relgnificant ro

e to trap eit

ap from clo

odels) the

e should in

he trap. Oparge sounddensate to

in a pot of

age 20 of

evision: 3

ate: 7 Oct

ing or plug

odic discha steam load , (2) excessi

able way tole in the tra

er stuck in

ing or plug

trap may di

rease briefl

n the valveill increas

ive steam.oiling wate

4

2010

ing a

ge.ve

verify

closed

ing a

charge

y, then

andin

,

Page 21: Steam Troubleshooting Guide Rev 3

7/23/2019 Steam Troubleshooting Guide Rev 3

http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 21/24

 

APPEN

 

The blofollowin

•  If thestrai

•  If the

too hsmalstea

•  If the

supplow.

• 

If the possi

•  If thethe cdue t

 

IX C (Blo

-down disc list shows

re is no diser is plugge

 discharge iigh due to i supply tubi supply pre

 discharge iy tubing, or 

 discharge bly the trap.

 discharge ircuit steamo improper

-Down Di

arge will plikely probl

harge: Thed.

s primarily proper roung, or a restssure is too

s weak: The a restrictio

ontains a lo 

s normal: Tload is tooouting, sma

STEAM

ROUBLE

charge)

ovide someems based o

ircuit is no

ondensate:ing; the cir riction; excow; the co

 circuit pres; the strain

 of contami

e steam traigh due to ill supply tu

EATING

SHOOTIN

 insight inton the strain

 supplied w

The steam tuit pressur ssive condedensate ret

sure drop isr is partiall

nants: Exce

 is failed omproper roing, or a re

YSTEM

G GUIDE

the steam cr discharge.

ith steam; t

ap is faileddrop is too

nsate is beirn pressure

too high du clogged; t

sive debris

en; the steating; the cir triction.

onditions in.

e circuit is

closed; thehigh due tog routed inis too high.

e to imprope steam sup

has built up

m supply pr cuit pressur 

age 21 of

evision: 3

ate: 7 Oct

 the circuit.

lugged, or

ircuit steaimproper roo the circui

r routing, s ply pressur 

in the circu

essure is to drop is too

4

2010

The

he

load isuting,; the

allis too

t, and

low;high

Page 22: Steam Troubleshooting Guide Rev 3

7/23/2019 Steam Troubleshooting Guide Rev 3

http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 22/24

 

APPEN

 

The best probe thwith steasystem bfor measis used,temperatinsulated  Thermo

impacte

the meas1. 

2.  bS 

 

 

3. 

t4.  I

tr 

5. t

 Infrare

temperatnegative1. 

2. se

 

IX D (Te

method oft directly cm systems.y measurinring the sureat care m

ure; in gene.

ouple Met

 by the emi

urement. Inemove a semove dirt,ttach the thead is presseveral meth

For singlIf multiplthermocoFor small plastic zi

the thermeplace the iake sure the thermoco directly mmperatureading.ead the ther ermocoupl

 Gun Meth

ure, but exty impactedemove a semove a litemove dirt,ote the mateel, rusty st

issivity se

perature

easuring tntacts the sIt is usuallythe surfaceface tempest be takenal, this is a

od: The thsivity of th

general, useall amountdebris, scalrmocoupled against t

ods of attac measureme measuremuple with a bore piping-tie or a me

ocouple beasulation ovt there are

uple.asuring theeading. If

mocouple t type being

od: An infr 

a care must by the ambiall amountle insulatiodebris, scalrial and co

eel, fresh stting as appr 

STEAM

ROUBLE

easureme

e steam teeam. Howenecessary ttemperatur ature, ther to assure thcomplished 

rmocouple pipe and t

 the followif insulatio rust, insul

 bead to thee pipe/tracement maynt use a pieent over se appropriat when the etal hose cla

d from the cer the ther o air gaps t

trace or steaeasuring pr 

mperatureused.

red gun ca

 be used toent air tempf insulatio as possible rust, insuldition of thel, etc.) Reopriate for t

EATING

SHOOTIN

t Procedu

 perature iser, this typ measure t of the pipiocouples at the ambie

 by ensurin

method is ge piping ca

g procedur  from the pition remnaipe/trace isurface; ane used:ce of high-teral days ar  epoxy suctire circum p may be

lamp usingocouple anhat allow a

m piping,cess piping

ith a meter

successfull

revent the perature. In g from the pi while stilltion remna

e surface toer to the IRhe surface.

YSTEM

G GUIDE

e)

o have a tee of temper e steam teg/tracing.d infrarednt conditio that the ar 

enerally theeasily rem

e: ping/tracint, etc fromthe expose air gap wil

mperaturee desired ita JB weld.

ference of tsed. If usin

a layer of i the pipe/tr  bient air to

ait approxi, wait appro

that is prop

y be used to

ipe/trace teeneral use t pe/trace in txposing sut, etc from

 be measuregun manual

 perature gature equip

 perature athere are twuns. No mas are not ima being me

most accur in insulate

 in the areahe pipe sur  area. It is i

l cause erro

ape is usuals better to a

e pipe is ex a metal ho

sulating mace around tcontact the

ately 30miximately 2h

erly progra

 measure th

 perature fr e followinhe area to bficient areahe pipe sur  (stainlessand adjust

age 22 of

evision: 3

ate: 7 Oct

uge installeent is rarel given poin commonter which

 pacting thesured rema

te as it is n while perf 

to be measuace.mportant theous readi

ly adequate.tach the

 posed, a hese clamp, i

erial.e thermoco pipe/trace a

 before tak r before tak 

med for th

 pipe/trace

om being proceedure measured.

for the IR gace.teel, galvanhe IR gun

4

2010

with aused

t in theethodsethodipe

ns fully

trming

red.

at thegs.

vysulate

uple.ound

ng ang a

:

n.

ized

Page 23: Steam Troubleshooting Guide Rev 3

7/23/2019 Steam Troubleshooting Guide Rev 3

http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 23/24

 

3. r 

a4.  Itr 

5. t p

 Note thaadditionnote thatthermoc

 

e-insulate tmoved. Ma

ound the ar  directly mmperatureading.emove the imperatureipe/trace wa once the Il locationsthe IR gunuple and th

e area to beke sure that

ea to be measuring theeading. If

nsulation pas quickly all temperatu gun emissiy pealing b

emissivity ce IR gun; th

 

STEAM

ROUBLE

 measuredthere are no

sured.trace or steaeasuring pr 

tch and qui possible asre.vity is set cack existingn be calibr  IR gun ca

EATING

SHOOTIN

ith a patchair gaps th

m piping,cess piping

kly take theven brief

rrectly, itinsulationted by mea then be adj

YSTEM

G GUIDE

of insulatiot allow am

ait approxi, wait appro

 temperatur xposure to

ay be possind quicklyuring the susted to ma

 that can beient air to c

ately 30miximately 2h

e using the Ihe ambient

 ble to takeeasuring t

me surfacech the ther 

age 23 of

evision: 3

ate: 7 Oct

 easily andntact the pi

 before tak r before tak 

R gun. Tak air will imp

easuremene surface.

with both aocouple re

4

2010

uickly pe/trace

ng ang a

thect the

s inlso

ding.

Page 24: Steam Troubleshooting Guide Rev 3

7/23/2019 Steam Troubleshooting Guide Rev 3

http://slidepdf.com/reader/full/steam-troubleshooting-guide-rev-3 24/24

 

APPEN

 

Accuratediagnosiinstallinsuitableit will be The gauline at thlast elemThe gautee it is i

clearancMcMast 

The spec

•  3

• 

• 

2

•  1

•  5

• 

5

• 

± 

IX E (Per

ly measuring the opera a permaneemperatureapproxima

e screws ine end of theent of Conte must not portant th

 between tr-Carr. The

ifications o

” dial

ack connec

-1/2” Stem l

/2” NPT co

0-400oF te

oF subdivis

1% full scal

anent Ste

g the steamtion of a stet temperatugauge for tely $50 for

o a standar circuit. TheoTrace ande placed af t only the t

e gauge stefollowing p

Desc

3/4" St

Bu

WIK 

 the temper 

ion

ength

nection

 perature ra

ons

e accuracy

STEAM

ROUBLE

m Tempe

temperatuream circuit.re gauge atis applicatiach circuit.

 3/4” tee fitoptimal locthe return ter the steae and bushi

 and the inart list is cu

ription

aight Tee

shing

Gauge

ture gauge

ge

EATING

SHOOTIN

ature Gau

 at the endhe measurehe end of en. The total 

ting via a bation for the bing, or bet trap. If the

ng listed bel

side of the f rrent as of 4

Part Nu

44605

4513K 

3946K 

S

re:

YSTEM

G GUIDE

e)

f the circuitment procech steam ci cost of the

shing. Thetemperatur 

ween the regauge is toow be used

tting. All p-Oct-2010.

mber

155

347

118

 btotal:

 (Step 8) iss can be str rcuit. CSI hgauge and t

ee fitting cae gauge is eiurn tubing

 be installedin order to

rts can be o

Price

$2.24

$1.91

43.60

47.75

age 24 of

evision: 3

ate: 7 Oct

 crucial steamlined bys identified e fittings to

n then be plther betweend the steain the brancchieve prop

rdered thro

4

2010

in

ainstall

aced in-n the

trap.h of theer

gh


Recommended