Steam Piping design

By
Dr. Piyatida TRINURUK
1
MEE 325 Power Plant Engineering 1/2558

Steam Piping Design

Steam pipe sizing
Thermal expansion at high temperature
Condensate
Pipe installation and support
Insulation

Typical Steam Circuit

.
.
.
6





(
)

Specific Volume & Pressure of Saturated Steam

1.8
Specific Volume (m3/kg)

1.6
1.4
1.2

1
0.8
0.6
0.4
0.2
0

Steam Tables

6
7
8
Pressure (barg)

10

11

12

13

14

Enthalpy in kJ/kg
Gauge pressure
bar
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14

kPa
0
100
200
300
400
500
600
700
800
900
1000
1100
1200
1300
1400

Temp.

Water

Evaporation

C
100
120
134
144
152
159
165
170
175
180
184
188
192
195
198

hf
419
506
562
605
671
641
697
721
743
763
782
799
815
830
845

hfg
2257
2201
2163
2133
2108
2086
2066
2048
2031
2015
2000
1986
1973
1960
1947

Steam
hg
2676
2707
2725
2738
2749
2757
2763
2769
2774
2778
2782
2785
2788
2790
2792

Volume Dry
Sat.
m 3/kg
1.673
0.881
0.603
0.461
0.374
0.315
0.272
0.24
0.215
0.194
0.177
0.163
0.151
0.141
0.132

Piping codes and standards from

standardization organizations

ANSI (American National Standard Institute)

ASME ( American Society of Mechanical Engineers)
ISO (International Organization for Standardization)
DIN (Deutsches Institut fur Normung , the German
Institute for Standardization)

ASME Committee B31, Code for Pressure Piping

B31.1 Power Piping: piping typically found in electric power generating stations, in
industrial and institutional plants, geothermal heating systems, and central and district
heating and cooling systems;
B31.3 Process Piping: piping typically found in petroleum refineries, chemical,
pharmaceutical, textile, paper, semiconductor, and cryogenic plants, and related
processing plants and terminals;
B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids: piping
transporting products which are predominately liquid between plants and terminals and
within terminals, pumping, regulating, and metering stations;
B31.5 Refrigeration Piping: piping for refrigerants and secondary coolants;
B31.8 Gas Transportation and Distribution Piping Systems: piping transporting products
which are predominately gas between sources and terminals, including compressor,
regulating, and metering stations; and gas gathering pipelines;
B31.9 Building Services Piping: piping typically found in industrial, institutional,
commercial, and public buildings, and in multi-unit residences, which does not require
the range of sizes, pressures, and temperatures covered in B31.1;
10
B31.11 Slurry Transportation Piping Systems: piping transporting aqueous slurries
between plants and terminals and

Distribute at High Pressure

Smaller bore steam mains needed and therefore less heat (energy) loss due to
the smaller surface area.
Lower capital cost of steam mains, both materials such as pipes, flanges and
support work and labour.
Lower capital cost of insulation (lagging).
Dryer steam at the point of usage because of the drying effect of pressure
reduction taking place.
The boiler can be operated at the higher pressure corresponding to its
optimum operating condition, thereby operating more efficiently.
The thermal storage capacity of the boiler is increased, helping it to cope more
efficiently with fluctuating loads, and a reduced risk of priming and carryover

Water Hammer

How is Pipe Sized?

On the basis of:
Pipe Thickness
Fluid Velocity
Pressure Drop


Steam pipematerial

Pipes for steam systems are commonly manufactured from carbon

steel to Wrought Steel
The same material may be used for condensate lines, although
copper tubing is preferred in some industries.
For high temperature superheated steam mains, additional alloying
elements, such as chromium and molybdenum, are included to
improve tensile strength and creep resistance at high temperatures.
Typically, pipes are supplied in 6 meter lengths.

1.7 MPa
Cast iron :


232oC
Wrought iron : Carbon steel Cast iron

Carbon steel :

LIMITATIONS ON MATERIALS
Pressure limitation
Temperature limitations : Upper limits/ Lower limits.

15

Pipe size
Pipe size is specified by two designations:
Nominal pipe size (NPS) for diameter based on inches
The European (ISO) designation equivalent to NPS is DN
(diamtre nominal/nominal diameter/Durchmesser nach
Norm), in which sizes are measured in millimeters.
The term NB (nominal bore) is also frequently used
interchangeably with NPS
Schedule (Sched. or Sch.) for wall thickness.

NPS tables for selected sizes

17

Pipe schedule
Pipe at present is made in
standard
1000 P
Scheduel number
extra strong
S
double extra strong
P=
S=

internal design pressure in bar,

design stress in N/mm2, (MN/m2)

These schedule numbers bear a relation to the pressure rating of the

piping.
There are eleven Schedules ranging from the lowest at 5 through 10,
20, 30, 40, 60, 80, 100, 120, 140 to schedule No. 160.
For nominal size piping 150 mm and smaller, Schedule 40 (sometimes
called 'standard weight')

18

Pipe Thickness and Standard Sizes

t
Where:
t =
P=
D=
S=
y=

PD
2S Py

internal pressure design thickness (mm)

internal design pressure in bar,
outside diameter of pipe in mm
design stress in N/mm2, (MN/m2)
Coefficient
Table 104.1.2(A) Values of y

0.2 - 0.5 MPa

[m/s]
0.6 - 1.5
1.5 - 3.0
3.0 - 4.0

4 MPa

15 - 20
20 - 50
50 - 120

50-70

8-15

0.5 - 4 MPa

20

Steam Pipe Sizing Chart (kg/h)

Pressure Velocity
bar g
m/s

0.4

0.7

15
25
40
15
25
40
15
25
40
15
25
40
15
25
40
15
25
40
15
25
40
15
25
40
15
25
40

15
15.8
9
14
23
10
17
28
12
20
32
18
29
47
23
38
61
28
47
75
34
56
90
39
65
104
44
74
118

20
20.93
15
25
40
18
30
48
21
35
56
31
51
82
40
67
107
50
83
132
59
98
157
68
114
182
77
129
206

25
26.64
25
41
66
29
49
78
34
57
91
50
83
133
65
109
174
80
134
215
96
159
255
111
184
295
125
209
334

Pipe Size Nominal / Actual Inside Diameter

32
40
50
65
80
35.04
40.9
52.5
62.7
77.92
43
58
95
136
210
71
97
159
227
350
113
154
254
363
561
51
69
114
163
251
85
115
190
271
419
136
185
304
434
671
59
81
133
189
292
99
134
221
315
487
158
215
354
505
779
86
118
194
277
427
144
196
323
461
712
230
314
517
737
1139
113
154
254
362
559
188
256
423
603
931
301
410
676
964
1490
139
190
313
446
689
232
316
521
743
1148
371
506
833
1189
1836
165
225
371
529
817
276
375
619
882
1362
441
601
990
1411
2180
191
261
430
613
947
319
435
716
1022
1578
511
696
1146
1635
2525
217
296
487
695
1073
362
493
812
1158
1788
579
788
1299
1853
2861

100
102.26
362
603
965
433
722
1155
503
839
1342
735
1226
1961
962
1603
2565
1186
1976
3162
1408
2347
3755
1631
2718
4348
1848
3080
4928

125
128.2
569
948
1517
681
1135
1815
791
1319
2110
1156
1927
3083
1512
2520
4032
1864
3106
4970
2213
3688
5901
2563
4271
6834
2904
4841
7745

150
154.05
822
1369
2191
983
1638
2621
1142
1904
3046
1669
2782
4451
2183
3639
5822
2691
4485
7176
3195
5325
8521
3700
6167
9867
4194
6989
11183

Pipeline Capacity and Pressure Drop

P2

P1
Fluid Flow
L
P1 - P2
F (P ressure D ro p Facto r)
L
Where:
F
P1
P2
L

= Pressure factor
= Factor at inlet pressure
= Factor at a distance of L meters
= Equivalent length of pipe (m)

Pipe Sizing Example

Although the unit heater only requires 270 kg/h, the boiler has to supply
more than this due to heat losses from the pipe.

The allowance for pipe fittings

The length of travel from the boiler to the unit heater is known, but an
allowance must be included for the additional frictional resistance of the
fittings. This is generally expressed in terms of 'equivalent pipe length'.
If the size of the pipe is known, the resistance of the fittings can be calculated.

As the pipe size is not yet known in this example, an addition to the equivalent
length can be used based on experience.
If the pipe is less than 50 m long, add an allowance for fittings of 10% to 20%.
If the pipe is over 100 m long and is a fairly straight run with few fittings, an
allowance for fittings of 5% to 10% would be made.
A similar pipe length, but with more fittings, would increase the allowance
towards 20%.
24

In this instance, revised length = 150 m + 10% = 165 m

25

From factor 0.030, by following the row of figures to the right it will be seen that:
A 40 mm pipe will carry 229.9 kg/h.
A 50 mm pipe will carry 501.1 kg/h.
Since the application requires 286 kg/h, the 50 mm pipe would be selected.
Having sized the pipe using the pressure drop method, the velocity can be checked if
required.

26

Determine the pipe size using the nomogram

Inlet pressure = 7 bar g
Steam flowrate = 286 kg/h
Minimum allowable P2 = 6.6 bar g

nomogram

27

Nomogram

28

Pressure drop in pipe

The D'Arcy equation

29

Pressure Reducing Station

Pressure reducing valve

Steam separator
Flow

Separator

Strainer

Safety relief valve

32

Warm Up Loads/Running Loads

(kg per 50 m of Steam Main)
Steam
Pressure

Steam Main Size (mm)

(bar g)

50

65

80

100

125

150

200

250

300

350

400

450

500

600

9.5

15.1

19.7

28.1

38.1

49.4

71

105

139

164

216

272

320

436

9.3

11.3

14.1

16.5

20.6

24.5

31.5

39

46.5

51.5

60

64

72

88

9.9

15.7

20.4

29.2

39.6

51.3

77

109

144

171

224

282

332

463

9.8

11.9

14.6

16.9

21.3

25

33

41

49

54

62

67

75

90

10.4

16.5

21.6

30.7

41.7

54.1

81.1

115

152

180

236

298

350

488

10.9

13

15.7

17.7

22.5

26

36

45

53

59

67

73

81

97

10

11

Figures in italics represent running loads

Ambient temperature 200oC, insulation efficiency 80%

Temperature expansion of pipes

Dl = a L Dt
Dl= Expansion of pipe , in m
a =Linear Expansion Coefficient a x 10-6 (m/m oC)
L= Length of pipe ,in m
Dt= Temperature difference , in oC
For Temp. Range

-30 0 - 100 0 - 200 0 - 315 0 - 400 0 - 485 0 - 600 0 - 700

Mild Steel 0.1 - 0.2 % C

13

14

15

15.6

16.2

17.8

17.5

Alloy Steel 1% Cr % Mo

14

14.4

15.1

15.8

16.6

17.3

17.6

Stainless Steel 18% Cr 8% Ni

9.4

20

20.9

21.2

21.8

22.3

22.7

23

Example:
100 m of Mild Steel Pipe is used to transport steam 4 barg. If the pipe is installed at 30 oC,
determine the expansion
Linear expansion coeff. =15 x 10-6 m/m oC , Saturated temp. at 4 barg = 152 oC
The expansion can be expressed as
Dl= (15 x 10-6 m/m oC) x (100 m ) x ( 152 30 oC ) = 0.183 m = 183 mm.

Expansion Chart for Mild Steel Pipe

Length of pipe (mm)

Temperature difference oC/metre

Expansion of pipe (mm)

Temperature of Saturated Steam
bar g
o

7.5

10

15

20

25

30

120

133

143

152

158

162

183

200

214

225

235

Pipe Expansion

Expansion fittings
Full Loop

Omega Loop or lyre loop

Expansion loops

Steel Expansion Loops

Nominal Pipe Size (mm)

Expansion from Neutral Position (mm)

Welding
ends radius
=1.5 dia.

2W

Maximum pressure 17 bar

o
Temperature 260 C
W.Metres

Use of Bellows
Expansion Bellows

Steam Flow

Misalignment

Axial Movement

Expansion Joint / Expansion bellow

Expansion
Joint

40

Flash Steam

Live Steam
42

Flash Steam
Flash Steam
(Condensate)

SH SL
x 100 % Flash Steam
H

SH
SL
H

43

Flash Steam Curve

Pressure on traps bar

Flash steam pressure bar g

Atmospheric
Pressure

44
kg flash steam/kg condensate

Approximate Amount of
Flash Steam in Condensate

Approximate Amount of Energy

in Flash Steam

Flash
Steam
(15%)
Water
(50%)

Flash
Steam
(50%)

Water
(85%)

45

 (Steam Trap)

46

 (Steam Trap)

1.
water hammer ()

2.

3.

47

48


(Mechanical Trap)
()
- 2

1.

49


(Mechanical Trap)
1.
2. (Bucket)

Open top bucket steam trap

Inverted bucket steam trap

50


(Thermostatic Trap)

2
1. (Bellows)
2. (Bimetal)

Bellow steam trap

Bimetals steam trap

51


(Thermodynamic Trap)
(Flash steam)

- 2
1.
2.

52

53

Principle of steam traps

54

55

-
-

-

56

1.
()
(back pressure)
2.
( )
()

3. 100
oC

57



1.
2.
3.
4.
5.
6.
7.
8.
9.
58

1.

2.

1.
2.

1.
2.

3.

1.

59

1.
2.

1.

60

Steam trap installation

61

Steam trap installation

62

Steam trap installation

63

 Condensate

64




1.

2.

3. U
U

4.
water hammer
5.
6.
(drain
separator)

65

 Header

66

Expansion
Loop
Omega loop

67


1.

2
1.1

1.2

68


2.


2.1


-
2.2

3.

69

1.

2.
3.

70

1.

2.
3.

.
.
.

71

1.7.2
back pressure drain recovery

drain
(recovery tank)


3
1

73


2
4-5
80 oC

74


3 1 2

75

Pressure Reducing Station

Pipe Alignment and Drainage

Flow

Separator

Water hammer
Sagging Main

Condensate

Slug of water from

condensate

Vibration and
noise caused by
waterhammer

Relaying to Higher Level

Fall 1/250

Steam

Relay
to high
level

30 - 50m

Drain Points

Steam Flow Flow

Ineffective, and Proper Drain Points

Steam Flow
Condensate

Cross
Section

Correct
Pocket
25/30m

Steam Trap Set

Steam Flow
Cross Section

Incorrect

Steam Trap Set

Steam Line Reducers

Correct
Steam

Condensate

Steam

Incorrect

Condensate

Strainers
Control Valve
Strainer

Branch Connections

Steam

Steam

Condensate

Incorrect

Correct

Drop Leg

Main

Shut Off Valve

Trap Set

Reverse Gradient on Steam Main

30-50m
Steam Velocity up to 40 m/s

30-50m
Increase in Pipe Diameter So
That Steam Velocity Is
Reduced to 15 m/s

Air Venting
Balanced Pressure
Air Vent

Steam Main

Air

Thermodynamic
Steam Trap Set

87


1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

88


1. Flake Insulation

2. Ferrous Insulation
Rock Wool, Alumina Silicate
Asbestoses
3. Granular Insulation Calcium Silicate
Diatomaceous Earth
4. Cellular Insulation
5. Reflective Insulation Sheet
Stainless Steel

89

(Rock
Wool)

Diatomace
ous Earth

kCal/m h oC
(oC)
550
350

0.053-0.056
0.048-0.053

400

0.055-0.065

400-600

0.039-0.048

250
500

0.082-0.084
0.083-0.097

90

(Glass
Wool)

1 8K-24K
2 10K-96K
3 96K
1

Pearlite

1
2

(oC)

kCal/m h oC

0.040-0.054
0.036-0.057
0.040
0.037
0.045

650

0.053
0.065

650

0.053

300-350

91

-
-
-
-
-

-
-
-
-
-

-
-
-

-
-

92

()

93



1. Diatomaceous Earth

2.
2

3.

94


1.
2.
3.
4. ()
5.
6.
7.
95

0.056-0.057
650 oC

0.045-0.055
650 oC

0.041-0.043
350 oC

pH 8-12.5
Cl2 120 ppm

pH 7-9

pH 7.5-9

10-20%

96

97

98