POWER

EQUIPMENT

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INSTRUCTOR:
ROBERT A. MCLAUGHLIN
ZAILI THEO ZHAO

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PIPING, VALVES
& STEAM TRAPS
LEARNING OBJECTIVES
 Understanding of piping systems, classifications, sizing

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and grades, including tubing identification. 
 Identify the types of valves and their applications and
limitations in typical piping system. 
 Identify the three basic types of steam traps. 

 Define the functions and limitations of various steam

traps. 
 Discuss leading causes for steam trap malfunctions and
how to repair defective units. 

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PIPING SYSTEMS
 Piping is used to connect the various units of machinery and

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equipment
 Includes:
 Sections of pipe
 Types of fittings to join piping
 Valves to control flow
 Can also contain other accessories such as: vents, drains, traps, strainers,
gages, relief valves, instruments, etc..
 Piping Design Considerations
 Type of fluid being transferred
 Operating pressures and temperatures
 Amount of fluid delivered
 Rate of fluid delivered
 These conditions determine the type materials, valves, fitting 3
and thickness of pipe or tubing
PIPING SYSTEMS
 Governing factors for piping design

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 Federal and private regulatory agencies
 ASME (American Society of Mechanical Engineers)
 Concerns all piping connections to power boilers with superheaters.

 Boiler external piping is required to conform to the standards.

 Most other agencies adopt these standards.

 ASTM (American Society of Testing Materials)

 Covers minimum standards for piping systems in power plants, pulp and

paper mills, and other industrial plants.

 ABS- American Bureau of Shipping-

 A classification or insurance company for ships.

 ABS sets the piping standards for ships, however they used ASME and

ASTM as the source of there rules. 4

 USCG- rules defer to the ABS.
PIPING SYSTEMS
 These codes cover minimum safety requirements for

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the :
 selection of materials
 Dimensions

 Design

 Fabrication

 Construction

 Testing of piping systems

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PIPING CONNECTIONS -
THREADS
 Low pressure applications, steam, water, lube oil,

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etc.
  Threads are NPT (National Pipe Tread) See sizing chart on
the next page
 NPT are tapered threads-
 ¾˝ per foot

 Before threads are engaged, the

male threads are covered with a
liquid, paste, or tape (Teflon) to :
 Lubricate the threads
 Help seal the joint

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THREADS
 “male” and “female” threads allow the joint to be engaged by hand

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a distance shown as F in the drawing below.   
 When tightened with a wrench the male threads should extend into
the female close to the distance E or the effective thread length.
 The last few threads will be imperfect.
 USCG prohibits the use of threaded joints in systems which the
fluid temperatures are over 925oF.

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THREADS
  Male threads: 

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 Measure the outside diameter of the large portion of the
thread at "A";
 Find figure nearest this dimension in column 1 or 2 of chart.
 The dimension in column 3 will be your nominal pipe thread
size.
 Female Threads:
 Measure top diameter of thread at "B";
 Find figure nearest this dimension in column 1 or 2 of chart.
 The dimension in column 3 will be your nominal pipe thread
size.
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 Normal
OD Fraction Inch
Actual (decimal) engagement for
     (for quick Pipe Thread Size Threads per Inch 
Inch. tight joint
reference only)
(dimension "C")
5/16 0.3125 1/16 0.2611 27

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13/32 0.405 1/8 0.2639 27

35/64 0.540 1/4 0.4018 18

43/64 0.675 3/8 0.4078 18

27/32 0.840 1/2 0.5337 14

1-3/64 1.050 3/4 0.5457 14

1-5/16 1.315 1 0.6828 11-1/2

1-21/32 1.660 1-1/4 0.7068 11-1/2

1-29/32 1.900 1-1/2 0.7235 11-1/2

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2-3/8 2.375 2 0.7565 11-1/2

PIPING CONNECTIONS -WELDED
 Weldingsections of pipe together.

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 Two methods of attachment:
 Buttjoint
 Socket-welding joint

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PIPING CONNECTIONS -
FLANGED
 A flange allows two pipes to be mechanically connected

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together
 Or a pipe to be mechanically connected to a valve, tee, or
other piece of equipment.
 The principle of a flange is to use a mechanical force to
pre-load the gasket sufficiently so that when internal
pressure is applied, there is enough contact stress
between the flanges and gasket to maintain a seal.
 The flange itself needs to be connected to the pipe.
 This is usually achieved by welding, though threaded and
other weldless connections also exist.
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FLANGED
 Types of flanges

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include
 WELDNECK
 SLIP-ON
 SOCKET WELD
 THREADED

 are common
types.

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FLANGED
 Thejoints between flanges have to have gaskets

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between the faces of the flanges.
 Gasket material will depend on the fluid in the system
 Most are cut from sheet gasket material, which comes in

different thicknesses, 1/32˝, 1/16 ˝, 1/8 ˝ are common

thicknesses
 Another type of gasket that can be used is the crush type

 Also known as Flexitallic gaskets for the company that

developed them
 Have steel outer ring reinforcing ring and a center portion

that is designed to be crushed. 

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FLANGED
 The flange faces must be aligned properly

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 The bolts must be tightened in the proper sequence
 The proper bolt diameter is 1/8 ˝ smaller than the flange bolt hole
dia.
 The proper bolt length is with 2-3 threads of the bolt extending
through the nut
 Compression Fittings- Seamless alloy tubing like for
hydraulic lines and lube oil lines
 Flared fittings- Tubing, copper, Air lines

 Soldered- low pressure, copper and brass water lines,

refrigerant
 Cemented- PVC, low pressure, drain lines 14
PIPING MEASUREMENTS
 To accurately describe pipe, you need the following

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information:
 OD- Outside Diameter
 ID- Inside Diameter
 OD-ID= Wall Thickness or Schedule
 Schedule is identified by
 standard schedule 40
 Extra Strong Schedule 80
 Double Extra Strong Schedule 160
 Other schedules Schedule 20, Schedule 120
 The higher the number, the thicker the pipe
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PIPING MEASUREMENTS
 Pipe is measured by nominal dimension

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 Called iron pipe size (IPS) and wall thickness
 Nominal means close to but may not indicate actual dimension

 Sizing from 1/8˝ to 12 ˝ are known by their nominal inside

diameter.
 The nominal outside diameter is standard regardless of schedule or
wall thickness.
 An increase in the schedule results in a decrease of the inside diameter.

 12 ˝ and over is designated by the actual OD, the wall thickness,

and the weight per foot.
 Pipe can also be described by its class of use:
 Class 1 pipe- good on systems of 150 psi and above, and 150oF and
above
 Class 2 pipe- good on systems below 150 psi and 150oF.

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PIPING MEASUREMENTS
 Tubing is measured by OD and wall thickness.

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 For example:

 Copper tubing wall thickness designated by letters

 Type K
 Type L

 Type M

 Type K copper tubing is the thickest, L is medium, and M is the

thinnest.

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PIPING FITTINGS
 Fittings are used in piping systems to:

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 Redirect the flow of fluid- 45o Elbows, 90o Elbows,
 Extend a straight line of flow- Couplings
 Split flow- Tees, Y connectors
 Allow for easy access to parts of the system- Unions
 Fittings may be installed by threading, welding, brazing, or
the fittings may be flanged.
 It really depends on the types of fluid, the system pressure, and the
system temperature as to what connection method will be used.
 Unions by design can be installed two ways; however there is only

one correct way (cover in class).

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PIPE SYSTEMS
 All piping systems need to have

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support.
 The can be from the top, sides or
underneath piping system.
 The will be installed is such a way
as to allow for support of the piping
in the system, plus the weight of
the fluid contained within.
 Must allow for expansion of the
system piping
 Types of supports:
 Spring
 Solid clamp

 Roller
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VALVES
 Purpose:to control

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system fluid flow for
 Maintenance
 Operation
 Casualty Control
 Proper
procedure for
opening
 Open fully then back off ¼
turn.
 Valve won’t jam
 The next person won’t try
to open it further

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VALVES
 Major components

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 Disk attached to stem.
 Disk seats against a seating surface
in the body
 Seat-
 The seat and disc of valves used for high
temperature service are often surfaced
with a hardened material
 Valve Body-
 Bonnet
 Stuffing Box
 Packing gland or packing nut
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 Valve wheel (Hand wheel)
TYPES OF VALVES - GLOBE
 Disc attached to stem

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 Disc seats against a seating surface
 May be fully open & closed, or partially
open
 Good for throttling.
 Large pressure drops across globe
valves, especially when throttling.
 Should be installed so that the flow
comes from under the seat.
 System pressure will assist in opening the
valve
 If the packing needs attention, there will be
no system pressure in the bonnet of the
valve.
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GATE VALVE
 Flat (parallel) or tapered gate

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interposed perpendicular to axis of
flow.
 Allows for straight through flow with
little restriction or pressure drop.
 Not practical for throttling
applications (the disc will vibration &
chatter)
 Operate fully open or closed.
 Come in a wide variety of sizes and
types
 Rising Stem
 Non Rising Stem
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 NEEDLE POINT VALVES
 For fine

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adjustment of
flow.
 Tapered point
at the inside
end of the
valve stem.

 Used for
throttling,
especially
when small
quantities of
gas or liquid
are to be
flowing. 25
BUTTERFLY VALVE
 Lightweight, less space required than a gate

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or globe.
 Quick acting (requires only ¼ turn.)
 Can be used to throttle.
 Low pressure application
 Smaller place.

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CHECK VALVES
 Some are automatically operated with no hand

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wheels or stems and some have the capability
of being shut off.
 Used to prevent return or back flow

 Several Types
 Lift Check
 Swing Check
 Ball
 Stop Check Valves (can be positively shut off)

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BALL VALVES
 Quick opening (1/4 Turn)

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 Excellent for full flow applications
 Can also be used for throttling
 The fluid flow acting on the partially exposed ball can cause
erosion.
 High pressure

  plug valve

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STRAINERS
 Prevents the passage of grit, scale,

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marine life, and other foreign matter
that could obstruct pump suction
valves, throttle valves etc
 Baskets can be removed for easy
cleaning.
 Simplex — only one basket, flow must be
stopped to clean
 Duplex — two baskets — flow may be
diverted to allow cleaning of off-line
strainer
 Y-Strainers
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STEAM TRAPS
  Steam traps are used is systems to

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 Drain condensate from heat exchangers
 They hold steam in heat exchangers until it has completely collapsed
to condensate.
 Allows latent heat available in steam to be exchanged

 They are used in low points of steam piping systems

help avoid water hammer
 Three main functions of steam traps are
 Allow condensate which was steam to collect and
flow back to the condensate system.
 Vent air and other gases
 Prevent the escape of steam- loss of available latent
heat. 30
STEAM TRAPS AND PIPES
 A steam trap is an automatic valve

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 it senses the difference between steam and condensate.
 The trap discharges the condensate
 withlittle or no loss of steam,
 which contributes to high operating efficiency.

 Steam traps are divided into three main groups:

 thermostatic
 mechanical
 thermodynamic

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THERMOSTATIC TRAPS
 It measure temperature

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 The balanced-pressure thermostatic trap
has a liquid-filled bellows that expands and contracts.
 When steam is in contact with the bellows
 causes the bellows to expand
 closes the valve

 If condensate or air is in contact with the bellows,

 bellows contracts and condensate is discharged
 Steam pressure does not affect the operation of this trap,

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THERMOSTATIC TRAPS

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THERMOSTATIC TRAPS
 The bimetallic trap also works according to the

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thermostatic principle.
 Two strips of suitably different metal bonded together
 The top strip expands more than the bottom one when heated
 allowing cool air and condensate to pass through

 As steam enters the traps and heats up the bimetallic

strip, the strip bends and closes off the valve.

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THERMOSTATIC TRAPS
 The liquid expansion thermostatic trap is

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operated by the expansion and contraction
of a liquid-filled thermostat
 When the steam is turned on, air and condensate pass through the
open trap.
 As the condensate temperature increases, the oil in the thermostatic
element expands and closes off the valve.
 An adjusting nut positions the valve relative to its seat, which
allows the trap to be set at a given temperature, usually 212℉,
or lower.
 Some liquid expansion traps are used for freeze protection.
When the temperature drops to 40℉, the trap opens, creating
enough flow to prevent freeze-up. 35
MECHANICAL TRAPS
 Mechanical traps distinguish between steam

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and condensate by their different densities.
 Various floats are used to operate the discharge
valve.
a ball floats on the surface of the condensate
 as the condensate level drops,
 ball covers the discharge passage
 prevents the loss of steam

 Air must be removed for the trap

 can be vented automatically form the float trap

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MECHANICAL TRAPS

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 Figure shows a float-and-thermostatic trap
 Float rises when condensate enters, opening the valve
 The valve closes if there is no condensate in the trap
 If there is a temperature drop caused by air, the valve opens.
 Element expands and closes when steam enters the trap.
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MECHANICAL TRAPS
 The inverted bucket trap

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 When system condensate enters
 bucket is at the bottom and valve open
 Air vented through a small hole on top of the
inverted bucket
 water level rises on both the inside and outside of
the bucket
 As steam fills the inverted bucket and makes it
float, close valve.
 Steam slowly escapes out of the bucket through the
vent hole.
 If the escaping steam is replaced by condensate,
 bucket sinks
 opens the valve

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THERMODYNAMIC TRAPS
 Or disk traps,

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 identify steam and condensate by the difference in
their kinetic energy or velocity as they flow
through the trap
 Low pressure flash steam
 pushing down on the large surface on top of the
disk
 overcomes the force of the live steam pushing up
in the smaller, exposed disk area.

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THERMODYNAMIC TRAPS

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THERMODYNAMIC TRAPS
 After startup, cool condensate lift the disk off

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its seat
 As the temperature of the condensate increases,

 Some of it flashes into steam

 The mixture of steam and condensate flows outward across
the underside of the disk.
 Because flash steam has a larger volume
 the flow increases as more flash steam is formed
 high velocity causes a low-pressure area

 to be formed under the disk and

 the expanding flash steam exerts pressure on top of the disk,

 forcing the disk downward and stopping all flow 42
THERMODYNAMIC TRAPS
 although the flash steam pressure is

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much lower
 but the large exposed area

 As the flash steam above loses heat,

some of it condenses, reducing the
pressure above the disk.
 The disk is again lifted off its seat,
and the cycle repeats itself.

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THANK YOU

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