Replace Failed Steam Traps Upstream of the Condensate Pot

Follow these steps to replace failed steam traps and eliminate thermal instability in the condensate return system:

1. Safety Precautions: Isolate the steam line by closing the upstream and downstream isolation valves. Apply lockout/tagout (LOTO) procedures. Allow the system to cool sufficiently to prevent thermal burns.
2. Removal: Using appropriate pipe wrenches, loosen the union fittings or flange bolts connecting the failed trap to the piping. Carefully remove the trap, keeping a collection container nearby to catch any residual hot condensate.
3. Inspection: Inspect the pipe threads or flange faces for corrosion or debris. Clean the sealing surfaces to ensure a tight connection for the new unit.
4. Installation: Install the new steam trap, ensuring the directional flow arrow on the trap body matches the direction of the condensate flow. Tighten all fittings to the manufacturer’s specified torque.
5. Verification: Slowly open the upstream isolation valve to pressurize the line. Observe the trap discharge during normal operation; a properly functioning trap should cycle periodically to discharge condensate without blowing continuous live steam. Verify the cessation of water hammer noise in the condensate pot.

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