§120.6(i) applies to new industrial facilities where the steam trap operating pressure is greater than 15 psig and the total combined connected boiler input rating is greater than 5 million Btu/hr. §120.6(i) also applies to new steam traps added to support new, non-replacement, process equipment in existing industrial facilities where the steam trap operating press is greater than 15 psig and the total combined connected boiler input rating is greater than 5 million Btu/hr. Existing steam traps that are being replaced due to failure are not required to meet §120.6(i). An exception is given to steam traps where steam is diverted to a steam system of lower pressure for use when the steam trap fails open, as might be found in a cascading process where steam is flashed to a lower pressure process. These traps would be exempted from the requirements of this section. However, the traps on the lowest pressure section which are discharging to the drain or condensate system are still covered.
There are four main mandatory requirements in this section:
a. Central steam trap fault detection and diagnostic monitoring - §120.61(i),
b. Steam trap fault detection - §120.6(i)2,
c. Steam trap strainer installation - §120.6(i)3, and
d. Steam trap system acceptance - §120.6(i)4.
There are two requirements for steam trap monitoring systems:
1. Provide status updates of all fault detection sensors to the central monitoring station at least every 8 hours, and
2. Automatically display an alarm that identifies which steam trap has a fault.
This requirement indicates that steam traps must have automatic fault detection sensors that can communicate with the central steam trap monitoring system described in §120.6(i)1.
This requirement identifies two options for meeting steam trap strainers:
•The strainer and blow-off valve must be integrated into the steam trap, or
•The steam trap must be installed within 3 feet downstream of the strainer and blow-off valve.
Before an occupancy permit is granted for compliance with §120.6(i) the equipment and systems should be certified as meeting the Acceptance Requirement for Code Compliance, as specified by NA7.19. A Certificate of Acceptance shall be submitted to the enforcement agency.Prescriptive Measures
There are no prescriptive measures for steam traps.
Section 120.6(i) applies to new steam traps added to support new, non-replacement, process equipment in existing industrial facilities where the steam trap operating press is greater than 15 psi and the total combined connected boiler input rating is greater than 5 million Btu/hr. If new steam lines including steam traps are added as part of an addition or alteration to an industrial facility, these steam traps are required to meet §120.6(i) as described above.
Example 10-81
A manufacturing facility has a 100 psig steam system served by three boilers, each rated at 3 million Btu/hr input rating and 2.5 million Btu/hr output rating. Two boilers are active, and one boiler is a back-up.
Question 1: What is the combined total rating of the system?
Answer: The combined input rating is 9 million Btu/hr; it includes all boilers physically connected to the steam piping system including back-ups. Since the input rating of this steam system is greater than 5 million Btu/hr, it is large enough for the steam trap FDD requirements to apply.
Question 2: For the previously described facility, if an existing 100 psi steam jacketed kettle is replaced with a new steam jacketed kettle and steam trap, is the steam trap on this system required to be accompanied by a strainer with blow-off valve and steam trap FDD device?
Answer: No. This steam trap supports replacement of existing equipment.
Question 3: For the previously described facility, if a new 100 psi steam jacketed kettle is added to this facility, is the steam trap on this system required to be accompanied by a strainer with blow-off valve and steam trap FDD device?
Answer: Yes. This steam trap is part of new process equipment installation. A strainer with blow-off valve would be required to protect the steam trap, along with a steam trap FDD device and the central console for displaying the state of all steam traps required to have FDD monitoring.
Question 4: For the previously described facility, a new hot water generator is installed. The main steam pressure is reduced to 5 psig upstream of the inlet of the hot water generator. Would a strainer with blow-off valve and steam trap FDD device be required for this system?
Answer: No. the steam trap in question is served by 5 psig steam, this is less than the 15 psig operating pressure threshold for each steam trap at which this requirements applies.