URIBE TUTE CY Steam Tracing The temperature of process liquids being transferred through pipelines often must be maintained to meet the requirements of a process, to prevent thickening and soldifica- tion, or simply to protect against freezeup. This is achieved by the Use of jacketed pipes, or by attach- ing to the product line one or more separate tracer lines carrying a heating medium such as steam or hot water, ‘The steam usage may be rel- atively small but the tracing system is often a major part of the steam installation, and the source of many problems. Many large users and plant contractors have their own inhouse rules for tracer lines, but ‘the following guidelines may be Useful in other cases. We have dealt only with extemal tracing, this being the area likely to cause difficulties where no existing experience is available. External tracing is simple and therefore cheap to install, and fulfils the needs of most processes. External Tracer Lines ‘One or more heat carrying lines, of sizes usually from 3/8" up to 1" nominal bore are attached to the main product pipe as in Fig. 6. Transfer of heat to the product line may be three ways—by conduction ‘through direct contact, by convec- tion currents. in the’ air pocket ‘formed inside the insulating jacket, and by radiation. The ‘racer lines may be of carbon steel or copper, or sometimes stainless steel Where the product line is of a particular material to suit the fluid itis carrying, the material for the ‘tracer line must be chosen to avoid electrolytic corrosion at any contact points, For short runs of tracer, such as around short vertical pipes, or valves and fitings, small bore cop- per pipes, perhaps 1/4" bore may be wound around the product lines as at Fig. 7. The layout should be arranged to give a continuous fall along the tracers as Fig. 9a rather than Fig. 9b, and the use of wrap around tracers should be avoided ‘on long horizontal lines. Arun of even 100 ft. of 6 inch product line will have a total of about 500 to 600 ft. of wrap around tracer, The pressure drop along the tracer would be very high and the temperature at the ‘end remote from the supply would be very low. Indeed, this end of the tracer would probably contain ‘only condensate and the temper- ature of this water would fall as it gives up heat. Where steam is resent in the tracer, lifting the condensate from the multiplicity of low points increases the problems associated with this arrangement. Aluminum oi Figure 6 ‘Tracer Attached To Product Line | Figure 9 Continuous Fall On Wrap Around Tracer Figure 7 ‘Small Bore Tracing Wraped Around Vertical Product Line > Y Sift Figure 10 Attaching Tracer To Line Figure 104 Continuous Weld Figure 8 Clipping Tracer Around Bends Lagging Hi conducting Paste Figure 10¢ Heat Conducting PasteSteam Tracing Clip On Tracers In these cases the tracer is Insulation The simplest form of tracer is one sometimes Iaid along the top of The insulation must cover both that is clipped or wired on to the the pipe rather than at the bot- the product line and the tracer but main product line. Maximum heat tom, which greatly simplifies the itis important that the air space flow is achieved when the tracer welding procedure. Advocates of remains clear. This can be isin tight contact with the product this method claim that this loca- achieved in more than one way. line. The securing clips should be tion does not adversely affect the f° The craduct line and tracer no further apart than 12"to 18" on heat transfer rates. taathet be wrapped witha 3/8" tracers, 18" to 24 on 1/2 minum foil, or by galvanized and 24"t0 96" on 3" andlarger, Meat Conducting Paste Paley wang The tracer pipes can be liter- fe" an sqvantage to use a heat and the insulation is then ally wired on, but to maintain Po, dlicting paste to fl the normal applied outside this sheet. close contact it is better to use fof air gap as in Fig. 100, The Alternatively, small mesh gal- ither galvanized or stainless Not 2" 99P as in Fig. 1. The vanized wire netting can be steel bands, about 1/2" wide and paste can be used to improve S04" the same way a5 48 to 20 gauge tixness, One at Wansfr with any ofthe clp- real sheet Fig. Ha, very practical method is to Use @ essential that the surfaces are 2. ‘Sectional insulation, _pre- packing case banding machine. Wirebrushed clean before apply- ‘formed to one or two sizes Where tracers are carried around PESTER RY larger than the product main, ends particular care should be 1" the paste. can be used, This has the taken to ensure that good contact Spacer Tracing disadvantage that it can eas- i's maintained by using three oF The product being carried in the ily be crushed Fig. 11. ‘more bands as in Fig. 8. line can be sensitive to tempera- 3, Preformed sectional insula- Where itis not possible to use ture in some cases and it is then tion designed to cover both bands as at valve bodies, soft important to avoid any local hot product line and tracer can annealed stainless steel wire 18 spots on the pipe such as could be used, as Fig. 11c. gauge thick is a useful alternative. occur with direct contact between Preformed sectional insula- ‘Once again, any special needs to the tracer and the ine. tion ig usualy preferred to plastic avoid extemal corrosion or elec- This is done by introducing a material, because being rigid it trolytic action may lead to these strip of insulating material retains better thickness and effi- suggestions being varied between the tracer and the prod- ciency. In all cases, the insulation uct pipe such as fiberglass, should be properly finished with Welded Tracers mineral woo, packing blocks of waterproof covering, Most stl Where the temperature differ- an inert material tion is porous and becomes ence between the tracer and the Useless as heat conserving mate- Product is low, the tracer may be fal if itis allowed to absorb water. welded to the product line. This ‘Adequate steps may also be can be done either by short run needed to protect the insulation welds as Fig. 10a or by a contin- ‘from mechanical damage. uous weld as Fig. 10b for maximum heat transfer, Lagging 4 Product Lagging Tracer wre Noting a Figure 11 Insulating Tracer and Product LinesSteam Tracing ‘Sizing of External Tracers with equal conviction, thatit is per- Jacketed Lines The tracing orjacketing of any line feelly satisfactory to space the Ideally jacketed lines should be normally aims at maintaining the acers equally around the Ine. constructed in no more than 20 ft Contents of the line at a satisfac: Thon there are those who will lengths andthe condensate tory working temperature under endeavorto size their racers from removed from each section. all conditions of low ambient tem- 3/8", 1/2", 3/4" or 1" and even Steam should enter atthe highest perature with adequate reserve to larger pipe: while another school _ end so that there is a natural fall to meet extreme conditions. ‘of thought says that as tracers the condensate outlet as Fig. 12a. Remember that on some have only minute contact with the When it is considered exposed sites. with an ambient — Productline itwill ve much more impractical to trap each length, a Stil air temperature of say O'F, even distribution of heat ifalltrac- number of lengths up a total of the effect of a 15 mph wind will be eS ate from 1/2" pipe in multiples 80-100 ft. approx. may be joined to lower the temperature to ant meet the requirements. This together in moderate climates, equivalent of -36°F. does have the added advantage bul in extremely cold parts of the ‘of needing to hold a stock of only world 40 ft. should be the max- ‘one size of pipe and fitings rather mum. See Fig. 12b. Even 32°F in still air can be lowered to an effective 4°F with a 20 mph wind—circumstances man a varlely of sizes. Always avoid connecting Which must be taken into full con For those who like to follow solely through the bottom loop. Sideration when. studying tre this idea, Table 6 willbe usefulfor This can only handle the conden- tracer line requirements. most average requirements. sate and impedes the free flow of Details of prevailing condi- Type A would suffice formost Steam as Fig, 12c. As @ general tions ‘can usually be ebiained —_fusl oil requirements and would ude, . from the local meteorological also meet the requirement of ‘Although in most cases 1/2 office or civil air authority, those lines carrying acid, phenol, condensate outlet will be ade- water and some other chemicals, quate, itis usual fo make this the waco Soryclenene! uC somu aioe aca Gane azsae ga eee ee . tion as it simples instalation. bulthe problem which anseshere between the product line and i is what rule and whose thumb? ‘The steam prescureis impor. External Tracers Rules of thumb are generaly jgq,7M@.Se8™ PreSSUTE |S MPC. In norzontal runs, th steam wil based on the experiences of a cer- generally flow parallel to the prod- according tothe product temper. Sepraly low paral’ fo he prog: tain company on a particular Sccording fo f process and do not necessarily ‘a steam should enter from the high apply elsewhere. There are also For noneritical tracing Types —_ end to allow free flow of the con- widely differing opinions on the lay. A&B (Table 6).a steam pressure densate to the low end, ie. it cout: some say that multiple tracers of 50 psi would generally bo suit- should always be self-draining should all be below the centerline able. For Type C, a higher It is generally considered ofthe product line while others say, Pressure and a trap with a hot preferable fo fit one tracer on the discharge may be required. bottom of the line as Fig. 13a, two. tracers at 30° as Fig. 13b, three Table 6: Number of 1/2" (15mm) Tracers Used tracers at 45° as Fig) 18 ay Where multiple 1/2” tracers Type A “Type 8 y are used, they should be arranged Nonerileal Noten ele in loop fashion on elther side of capeengicin over stn nay When eon nay i ‘rowsoisoten my’ rcltmgntaeet eorctngesanen | {Re produetne, as Fig. 14 Inver ‘occur a temps below 75°F 75180°F 150-300°F i Product Number of 172" Number of 172" Number of 172" spaced uniformly, as Fig. 15a & b. Line Size ‘Tracers ‘Tracers Tr The maximum permissible length of tracer will depend to some extent on the size and initial steam pressure, but as a general guide 3/8" tracers should not exceed 60 fit. in length and the limit for all other sizes should be about 150 ft. Bends and low points in the tracer, as Fig. 16a should always be avoided. For example, if it is necessary to carry a tracer line round a pipe support or flange, “this should be done in the hori- zontal plane, Fig. 16b, ‘Where itis essential to mai tain the flow of heat to the product, the tracer should be taken up to the back of the flange Fig. 17, and the coupling should always'be on the center line of the flanged joint ‘The same applies to an it line run where the tracer has to be jointed. This can be done in two ways, Fig. 18 or Fig. 19. Each of these is preferable to Fig. 20 which could produce a cold spot. Where two tracers are Used it can be better to double back at a union or flange as Fig. 21, rather than jump over it Expansion Expansion in tracer lines is often overlooked. Naturally the steam heated tracer will tend to expand more than the product line. Where the tracer has to pass around flanges, the bends are Quite adequate to take care of the expansion, Fig. 22. Butwhere this does not occur and there is a long run of uninter- rupted tracer, it is essential to provide for expansion which can Steam Tracing PLEA uk me bu Steam Trap |, “ooo Figure 12a + Tattle Lines, Orained Separately Steam ! nae Stearn Figure 126 Trap Product Jacket ‘Steam tine Diameter Connection Ze _ 65mm 100mm 215mm 3 80mm 6 150mm 314° 20mm 700mm ‘6 150mm 314° 20mm 6 150mm ‘8 200mm 314° 20mm ‘8 _200mm 05 250mm TF _25mm 10" 250rm 12300 25mm General Installation 4 steam Fal = Le Realy Figure 13 Single and Multiple Tracing Pas be done by forming a complete loop, Fig. 23. Figure 12¢ Figure 14 Incortect Arrangement of Jacketed Lines Multiple Tracing Figure 15 Vertical Tracing meee @ 9 ao a === |= O a © Figure 21 isa Figure 16h Correct Arrangement Correct, ‘Arrangement Figure 19 for Tracerine Joints Figure 20 incorect Arrangement Dual Tracer Double Back Figure 23 Expansion Arrangements on Long TracersSteam Tracing ‘Tracer Steam Distribution Itis important that the steam sup- ply should always be taken from source which is continuously available, even during a normal shut down period. Tracer lines and jacketed pipe may have to work at any steam pressure (usually in the range between 10 and 250 psi, but always choose the lowest pres- sure to give the required product temperature. Excessively high pressures cause much waste and should only be used where a high product temperature is essential). To suit product temperature requirements, it may be necessary to use steam at different pres- sures. It should be distributed at the highest pressure and reduced down to meet the lower pressure fequromanis, A Rodong Vals can be used for this purpose, 24: Note: tmay be necessary to ‘team trace the valve body to pre- vent damage due to freezing. ‘A number of tracers can be supplied from one local distribu- tion header. This header should be adequately sized to meet the maximum load and drained at its low point by a steam trap as Fig 25. All branches should be taken off the top of this header, one local to the header, otherwise high Pressure drop may result The size of the header will, of ‘course, depend upon the steam pressure and the total load on the tracers but as a general guide, see Table 8: Tracer Trap Sizing Subcooled discharge traps are usually a good choice for tracer service. Tracing loads are approximately 10 to 50 Ib.fhr., and ‘each tracer requires its own low capacity trap. No two tracers can have exactly the same duty, so group trapping two or more tracers to ‘one trap can considerably impair the efficiency of heat transfer, see Fig. 26 and Fig. 27. Even with multiple tracers on fa single product line, each tracer should be separately trapped— Fig. 28. When branched tracers are taken to serve valves, then each should be separately trapped, Figs. 29, 30, 31 and 32. Figure 24 Spirax Sarco Reducing Valve IEE Steam Tap Figure 29 "Tp {8 (10mm) OD, 114" (Gm) Bors ‘Steam Trap 3/8: (10mm) 00 404" (6mm) Bore = branch to each tracer lino. These branches should be fitted with isolating valves. Don't undersize these branch connections (1/2" supply to even a 3/8" tracer will avoid undue pres- ‘Sure drop) and serve only tracers Figure 26 Steam Trap Incorrect Arrangement ‘ cro 4 Steam Recommended header size EER Figure 30 for supplying steam tracer ines ce a Hoader Size_ Number of 12" Tracers Steam Tap ae z Zs = 35 ae betel Figure 27 stam Top z Correct Arrangement Recommended header size Seam or condensate ines «Seem Header Size Number of 12 Tracere ET 7 Ups i i ca ————=$= Figure 31 Figure 28 Steam Trap Tracer Lines Around Pump CasingSteam Tracing Steam Traps For Tracer Lines __ if high back pressures are to be ‘Almost any type of steam trap avoided. Thus, the use of swept could be used to drain tracer back or “y" connections from trap RZ) lines, but some lend themselves discharges into common headers to this application better than oth. of generous size will help avoid ers. The traps should be Problems. physically small and light in Where the traps are exposed 4 BS weight, and as they are often to wind, rain or snow, or low = [ie (jdm) o0 ted in’ exposed positions, they ambient temperatures, the steam [J 418" (Gnm)Bore should be resistant to fost. The bubbles in the top cap of the trap JM} temperature at which the conden- can condense more quickly, ead- JF @ Steam Trap sate is discharged by the trap is ing to more rapid wear. Special [4 perhaps the most important con- insulating caps are available for Figure 32 sideration when selecting the fitting to the top caps to avoid Typical Instrument Tracing type of trap. this, Fig. 33. Seen Thermo-Dynamic® traps are In other non-critical applica- Important- the simplest and most robust of tions, it can be convenient and Getting Rid of the Muck all traps, they meet all of the energy efficient to allow the con- above criteria and they discharge densate to sub-cool within the condensate at a temperature tracer before being discharged. close to that of steam. Thus they This enables use to be made of fare especialy suitable on those some of the sensible heat in the tracing applications where the condensate, and reduces or even holding back of condensate in the eliminates the release of flash tracer line until it has subcooled steam. Temperature sensitive would be unacceplable. Tracers traps are then selected, using or jackets on ines carrying sul- either balanced pressure ot aie Uae fostna wil convort_ Bhuror aaphal_ ply these bimsale coments. is “muck” into a mobile sludge applications where the tracer ir Which is not adequately washed just be at steam temperature gigehh ye eae h Sumy uty Simply raining down ater slong ts whol lngth {any soretan diforenia such It must be remembered that 50°F below condensing tempera- It is most important that the every time a Thermo-Dynamic? tures, and tend to give a lines, are properly cleaned by trap opens, itdischarges conden- continuous dribble of condensate Blowing through with steam to an gato at the maximum. rate when hanling tracer loads, help. open end before diverting to the Corresponding to the differential ing minimize. the size of steam traps. pressure applied. The instanta- condensate line needed. They Unless this is done, the traps neous release rates of the steam are available either in maintain- wil almost certainly fail to operate flashing off the condensate can able versions, with a replaceable correctly and more time will be be appreciable, and care is need- element set which includes the Spent cleaning them out when the ed to ensure’ that condensate valve and seat as well as the Pipes delivered to the site may contain mill scale, paint, preserv- ing oils, etc. and during storage and erection will collect dit, sand, weld splatter and other debris, so that on completion, the average tracer line contains a consider- able amount of “muck.” plant is commissioned. retum lines are adequately sized bimetallic stack, or as sealed non-maintainable units as required. Figure 33 Insulating Cap for Thermo-Dynamic® Trap Balanced pressure traps nor- mally operate just below steam temperature, for critical tracing applications, see Fig. 34 The trap is especially suitable where small quantities of condensate are produced, on applications where sub-cooling is desirable, and where the conden- sate is not to be returned to the recovery system. Figure 34 Balanced Pressure Tracer Trap "7Steam Tracing A similar but maintainable type intended for use on instru ment tracer lines, where the physical size of the trap is impor- tant as well as its operating characteristics is shown in Fig. 35. Just as the distribution of steam is from a common header, it often is convenient to connect a number of traps to a common condensate header and this sim- plifies maintenance. As noted, the discharge should preferably enter the header through swept con- nections and the headers be adequately sized as suggested in Table 8 (page 16). densate. of Tracer where required for frequently used. These may be increased where high pressures and traps discharging condensate at near steam temperature are used, or decreased with low pressures and traps discharging cooler con- the simple direct acting tempera- ture control often provides an economic solution, This will give close control and since it is not necessary to provide either olec- tric power or compressed air, the first cost and indeed the running costs are low. Temperature Control Where it is essential to prevent overheating of the product, or constant instrumentation, automatic temperature control is viscosity’ is ‘On many systems, the sim- plest way to achieve control is to duce the temperature. Figure 35 Maintainable Balanced Pressure Tracer Trap. use a reducing valve on the steam supply to the tracer li jacket. This can be adjusted in the light of experience to give the correct steam pressure to pro- required product 18s oF Clearly this is an approximate way to control product tempera- ture and can only be used where the product flow is fairly constant. Where closer control is required, Case in Action: Product Steam Tracing with Temperature Control and Overheat Protection Benefits During steam tracing project design, it was found that five thousand feet of 2" product piping was to be traced with 150 psig steam. Product temperature was to be main- tained at 100°F, with maximum allowable temperature of 10°F and a minimum allowable temperature of 50°F, Of particular concern was the fact that the pipeline ‘would always be full of the product, but flow would be intermittent. Overheating could be a real problem. In add tion, the tracing system had to be protected from freezing. ‘Solution ‘The 5,000 feet of product piping was divided into 30 sep- arate traced sections including: a cast steel temperature regulator, a bronze temperature control valve used as high limit safety cutout, a sealed balanced pressure ther- mostatic steam trap, a vacuum breaker, and pressure regulators supplying steam to all 30 tracing sections. Each section operates effectively at the desired temperature, regardless of flow rate or ambient temperature, ‘The chance of product damage from overheating is mi imized and steam consumption is reduced through steam pressure reduction (150 psig to 50 psig) with the pressure regulator. ‘The product temperature is maintained at a consistent set temperature, maximizing process control under all ‘low conditions with the temperature regulator, Product damage from averheating is prevented through Use of the high limit safety cutout. The system will shut down completely, should the temperature regulator over- shoot its set point. ‘The tracing system is protected from freezing with the sealed balanced pressure thermostatic steam trap dis- charging to drain. Thorough drainage is also faciltated by the vacuum breaker.