Installation Manual

25 Steam system
Document ID WDAAA116787b

Date of issue 22.09.2011

Status Approved

Classification Confidential
INSTRUCTIONS
 Installation Manual

Table of Contents

25. Steam system........................................................................................................................................... 25-1

25.1. Steam mains........................................................................................................................................ 25-1
25.1.1. Removing air from steam lines...................................................................................................... 25-1
25.1.2. Removing condensate from steam lines....................................................................................... 25-1
25.1.3. Providing proper alignment and drainage..................................................................................... 25-2
25.2. Allowance for expansion...................................................................................................................... 25-4
25.2.1. L-bends & U-bends....................................................................................................................... 25-4
25.2.2. Steel bellows................................................................................................................................. 25-5
25.2.3. Pipe supports................................................................................................................................ 25-6
25.3. References to other instructions.......................................................................................................... 25-7

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 Installation Manual 25. Steam system

25. Steam system

25.1 Steam mains

25.1.1 Removing air from steam lines

At startup, cold lines are filled with air. Steam issuing from the source mixes with some of this
air, but it also acts as a piston — pushing the air to the remote end of each line. Air in steam
lines lowers the temperature for a given pressure, and calculated rates of heating may not be
met.
The most economic means for removing air from steam lines is automatically through
temperature-sensitive traps or traps fitted with temperature sensitive air venting devices.
These traps are placed at points remote from the steam supply. When full line temperature is
attained, the vent valves close completely.

25.1.2 Removing condensate from steam lines

As soon as steam leaves the boiler, some of it starts to condense due to heat losses from the
pipework. The rate of condensation is particularly heavy at startup when the pipework is cold.
Fig 25-1 is a diagrammatic representation of the way in which droplets of condensate can
build up in a straight pipe. Ultimately they can form a solid slug moving at the velocity of the
steam.

Fig 25-1 Condensate in a straight pipe GUID-E32A68FD-87AE-4DCB-80D2-9973F227EE31 v1

The resultant water hammer can cause severe damage to pipework and fittings. The likelihood
of water hammer occurring increases if the pipework is allowed to sag. This can occur when
pipe hangers fail or when the support is inadequate. There is the same sort of danger when
water is allowed to collect at low points in the pipework.
Fig 25-2 shows an example where the pipework is half flooded. This doubles the steam
velocity in the remaining free area of the pipe. The chance of slugs of water being picked up
to create water hammer conditions is thereby increased. At the same time, the restricted free
area will cause high pressure drops despite correct sizing of the pipework.

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Fig 25-2 Half-flooded pipe GUID-E36E6631-262E-4CD8-BC01-2BD1EA23B64C v1

25.1.3 Providing proper alignment and drainage

● In the past, steam lines were sloped to assist in clearing condensate, but the improved
draining is now not considered to be worth the difficulty and expense involved. Instead,
the pipe should be somewhat oversized and more frequent drainage points should be used.
● Saturated steam lines should be drained at regular intervals. The distance between drain
points depends on line size, location and the frequency of startup, but intervals of 30–50
m (100–150 ft) are usual. Lines should also be drained at all low points where condensate
can collect. Drain points are most effective where the pipework changes direction.
● To provide drainage in a straight length of pipe, a large bore pocket should be used as
shown in Fig 25-3. Droplets of water are generally carried past the small-bore tapping. Full-
bore pockets are ideal and are practical in pipework up to 100 mm (4") in diameter. For
larger pipes, the pocket can be two or three sizes smaller than the line being drained.

Fig 25-3 Drain pocket GUID-4B5063F1-91FB-40F0-B7AB-0C594B3E9CBD v1

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Installation Manual 25. Steam system

● Pipework should be arranged to avoid pockets where water can collect. Fig 25-5 shows
the incorrect use of a concentric reducer that allows condensate to collect. The correctly
installed eccentric reducer ensures that condensate can flow to the next drain point. Similar
problems can occur with some valves and fittings. All steam lines should be connected to
the upper side of the main pipe.

Fig 25-4 Standard steam trapping on a 46 pipe rack GUID-BFC81391-EA22-4425-A7AB-463D995A6BDD v1

Fig 25-5 Concentric/eccentric reducer GUID-3483564A-ACD7-41FC-87B9-D0DB17B380DD v1

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25. Steam system Installation Manual

● The strainer shown in Fig 25-6 is a potential cause of water hammer, or of wire drawing of
control valves; also much of the screening area is ineffective because it is out of the steam
flow. Strainers above 25 mm (1") should be fitted on their side to avoid these problems.
Globe valves of under and over construction can also form a weir and prevent condensate
from flowing to the next drain point if they are fitted in the “normal” position in a horizontal
line. Again, this can be avoided by fitting the valves on their side.

Fig 25-6 Strainer GUID-07EEAFFC-9F06-43C6-BFE3-C8105AFDB834 v1

25.2 Allowance for expansion

25.2.1 L-bends & U-bends

L and U bends are the most used expansion compensators in Wärtsilä plants.

NOTE
When installing L-bend and U-bend pipe supports, pay attention to the pipe
movement in the side to side direction.

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 Installation Manual 25. Steam system

Fig 25-7 L-bend GUID-CE837C11-5F7E-4A9E-9DEC-1756C64B75D4 v1

Fig 25-8 U-bend GUID-08339875-1BE5-4F63-80CA-C297FE20E704 v1

NOTE
For more details, see the installation instructions WDAAA116756 (Piping/ducting
supports).

NOTE
For information about the expansion allowance for boilers and other equipment,
see the manufacturer’s installation instructions.

25.2.2 Steel bellows

Steel bellows are used when there is not enough space available for L-bends or U-bends. It
is essential that the bellows are rigidly guided. This is because the steam pressure acting on
the cross-sectional area of the bellows tends to blow the bellows apart in opposition to the
forces produced by the expanding pipework.
Misalignment will cause the bellows to bend.

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Fig 25-9 Steel bellows GUID-F1532BF6-EC97-4E6C-BD44-61FD89F22698 v1

25.2.3 Pipe supports

Fig 25-10 Fixed and sliding steam pipe supports GUID-CB1E063D-C110-49A6-9736-F30C9479BE42 v1

NOTE
Refer to chapter 10 “Piping/ducting supports” for more information on Wärtsilä
standard supports for steam piping.

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 Installation Manual 25. Steam system

25.3 References to other instructions

Table 25-1 References to other instructions

Name of installation instruction DocId

Piping in general WDAAA116731
Trace heating WDAAA116779
Piping/ducting supports WDAAA116756
Cleaning and flushing of external piping WDAAA116767
Welding WDAAA116762

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 Wärtsilä is a global leader in complete lifecycle power solutions for the marine and energy markets. By
emphasising technological innovation and total efficiency, Wärtsilä maximises the environmental and
economic performance of the vessels and power plants of its customers. Wärtsilä is listed on the
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