Block 3 The Boiler House Steam Headers and Off-takes Module 3.

Module 3.8
Steam Headers and Off-takes

The Steam and Condensate Loop 3.8.1

Block 3 The Boiler House Steam Headers and Off-takes Module 3.8

Steam Headers and Off-takes

Shell boilers are made for capacities up to around 27 000 kg / h of steam. When loads in excess
of this are required, two or more boilers are connected in parallel, with an installation of four
or more boilers not being uncommon. The design of the interconnecting steam header is
highly important.
Figure 3.8.1 shows a common method of connecting four boilers: a method that is frequently a
source of problems.
B A

To
plant

1 2 Boilers 3 4

Fig. 3.8.1 Common four boiler layout - not recommended

Referring to Figure 3.8.1, with all boilers operating at the same pressure, the pressure at point A
has to be less than that at point B for steam to flow from boiler number 3 to the plant. Consequently,
there must be a greater pressure drop between boiler number 4 and point A than boiler
number 3 and point A.
Flow depends on pressure drop, it follows then, that boiler number 4 will discharge more steam
than boiler number 3. Likewise, boiler number 3 will discharge more than number 2, and so on.
The net effect is that if boiler number 1 is fully loaded, the other boilers are progressively
overloaded, the effect worsening nearer to the final off-take.
It can be shown that, typically, if boiler number 1 is fully loaded, number 2 will be around 1%
overloaded, number 3 around 6%, and number 4 around 15% overloaded. Whilst shell boilers
are able to cope with occasional overload conditions of 5%, an overload of 15% is undesirable.
The increased steam outlet velocity from the boiler creates an extremely volatile water surface,
and the level control system might fail to control.
At high loads, in this example, boiler number 4 would lock-out, throwing an already unstable
system onto the three remaining boilers, which would soon also lock-out.
The main observation is that this design of distribution header does not allow the boilers to share
the load equally.
The aim should be that the pressure drops between each boiler outlet and the header off-take to
the plant should be within 0.1 bar. This will minimise carryover and help to prevent overload
and lockout of boilers.
The layout shown in Figure 3.8.2 shows an improved design of a new header.

3.8.2 The Steam and Condensate Loop

Block 3 The Boiler House Steam Headers and Off-takes Module 3.8

To plant

Boilers 1 2 3 4

Fig. 3.8.2 Four boiler header design - improved layout

The header is arranged to discharge from the centre, rather than at one end. In this way, no
boiler will be overloaded by the header by more than 1%, providing the header pipework is
properly sized.
A better arrangement is shown in Figure 3.8.3 for an installation of four or more boilers, rather
like a family tree, where the load on each boiler is spread equally. This arrangement
is recommended for heavily loaded boilers, with sequencing control where one or more is
regularly off-line.
It is emphasised that correct header design will save much trouble and expense later.
Correct boiler header design on multi-boiler applications will always result in a well-balanced
operation.

To plant

Boilers 1 2 3 4

Fig. 3.8.3 Four boiler header design - recommended layout

Steam off-takes
Having considered the general arrangement of the steam header, the following conditions need
to be ensured:
o That dry steam is exported to the plant.
o That the warm-up operation is properly controlled.
o That steam is properly distributed to the plant.
o That one boiler cannot accidentally pressurise another.

The Steam and Condensate Loop 3.8.3

Block 3 The Boiler House Steam Headers and Off-takes Module 3.8

Water carryover
When a well-designed boiler generates steam under steady load conditions, the dryness fraction
of the steam will be high, approximately 96 to 99%. Changes in load that occur faster than the
boiler can respond will adversely affect the dryness fraction. Poor control of boiler water TDS,
or contamination of boiler feedwater, will result in wet steam being discharged from the boiler.
A number of problems are associated with this:
o Water in a steam system gives the potential for dangerous waterhammer.
o Water in steam does not contain the enthalpy of evaporation that the plant has been designed
to use, so transporting it to the plant is inefficient.
o Water carried over with steam from a boiler will inevitably contain dissolved and suspended
solids, which can contaminate controls, heat transfer surfaces, steam traps and the product.
For these reasons, a separator close to the boiler is recommended. Separators work by forcing
the steam to rapidly change direction. This results in the much denser water particles being
separated from the steam due to their inertia, and then encouraged to gravitate to the bottom of
the separator body, where they collect and drain away via a steam trap.

Warm-up
It is essential that when a boiler is brought on line, it is done in a slow, safe and controlled
manner to avoid:
o Waterhammer - Where large quantities of condensate lie inside the pipe and are then pushed
along the pipe at steam velocities. This can result in damage when the water impacts with
an obstruction in the pipe, for example a control valve.
o Thermal shock - Where the pipework is being heated so rapidly that the expansion is
uncontrolled, setting up stresses in the pipework and causing large movement on the
pipe supports.
o Priming - Where a sudden reduction of steam pressure caused by a large, suddenly applied
load may result in boiler water being pulled into the pipework. Not only is this bad for plant
operation, the boiler can often go to ‘lock-out’ and it will take some time to return the boiler
to operating status. The discharged water can also give rise to waterhammer in the pipework.
The warm-up period for every plant will be different and will depend on many factors. A small
low-pressure boiler in a compact plant such as a laundry, for example, could be brought up to
operating pressure in less than 15 minutes. A large industrial complex may take many hours. The
starting point, when safely bringing a small boiler on line, is the main stop valve, which should be
opened slowly.
On larger plants, however, the rate of warm-up is difficult to control using the main stop valve.
This is because the main stop valve is designed to provide good isolation; it has a flat seat that
means that all the force exerted by turning the handwheel acts directly onto the seat, thus ensuring
a good seal when under pressure. It also means that the valve is not characterised and will pass
approximately 80% of its capacity in the first 10% of its movement.
For this reason it is good practice to install a control valve after the main stop valve. A control
valve has a profiled plug, which means that the relationship between an increase in flow and the
movement of the plug is much less severe. Consequently the flowrate, and hence warm-up rate,
is better controlled.
An example of a control valve fitted after the boiler main stop valve is shown in Figure 3.8.4.
A typical warm-up arrangement may be that the control valve is closed until the boiler is required.
At this point a pulse timer slowly opens the control valve over a predetermined time period. This
arrangement also has the advantage that it does not require manpower (unless the boiler is
heated up from cold) over the boiler warm-up period, which may be during twilight hours.

3.8.4 The Steam and Condensate Loop

Block 3 The Boiler House Steam Headers and Off-takes Module 3.8

Control valve
Main stop valve Controller

Boiler

Fig. 3.8.4 Control valve after main stop valve

The subject of bringing boilers on-line is covered by the HSE guidelines in the UK.
On large distribution systems, a line size control valve is still often too coarse to provide the
required slow warm-up. In these circumstances a small control valve in a loop around an isolation
valve could be used. This also has the advantage that where parallel slide valves are used for
isolation, the pressure can be equalised either side of the valve prior to opening. This will make
them easier to open, and reduces wear.
Preventing one boiler pressurising another
From BS 2790, Section 8.8.3.
Where two or more boilers are connected to a common header, in addition to the boiler main
stop valve, a second valve shall be incorporated in the steam connection, and this valve shall be
capable of being locked in the closed position. This allows better protection for a decommissioned
boiler when isolated from the distribution header.
Unless a separate non-return valve is fitted in the steam connection, one of the two stop valves
must incorporate a non-return facility.
The objective of this section of the British Standard is to provide safe working conditions when
the boiler is shut down for repair or inspection.
Simple flap-type non-return valves are not suitable for this purpose, because small changes in
boiler pressures can cause them to oscillate, placing excess load on to one boiler or the other
alternately. This can, under severe conditions, cause cyclical overloading of the boilers.
Many cases of instability with two-boiler
installations are caused in this way. Main stop
valves with integral non-return valves tend to
suffer less from this phenomenon. Alternatively,
spring loaded disc check valves can provide a
dampening effect which tends to reduce the Steam Steam
problems caused by oscillation (Figure 3.8.5).
BS 2790 states that a non-return valve must be
fitted in this line together with the main stop
valve, alternatively, the main stop valve must
incorporate an integral non-return valve. Fig. 3.8.5 Typical disc type non-return valve

The Steam and Condensate Loop 3.8.5

Block 3 The Boiler House Steam Headers and Off-takes Module 3.8

Boiler related standards (UK)

Statutory instrument 1989 No. 2169 (The pressure systems and transportable gas containers
regulations 1989) with the associated guide and approved code of practice.
Specification for design and manufacture of shell boilers
BS 2790 of welded construction.
BS 1113 Specification for design and manufacture of water-tube steam generating plant.
BS 6759
(related to but not equivalent Specification for safety valves for steam and hot water.
to ISO 4126) Part 1
BS 759 Part 1 Specification for valves, mountings and fittings for steam boilers above 1 bar g.

Ensuring proper steam distribution

The starting point for the distribution system is the boiler house, where it is often convenient for
the boiler steam lines to converge at a steam manifold usually referred to as the main distribution
header. The size of the header will depend upon the number and size of boilers and the design
of the distribution system. In a large plant, the most practical approach is to distribute steam via
a high pressure main around the site.
High pressure distribution is generally preferred as it reduces pipe sizes relative to capacities and
velocities. Heat losses may also be reduced due to lower overall pipe diameters. This allows
steam supplies to be taken from the main, either direct to high pressure users, or to pressure
reducing stations providing steam to local users at reduced pressure. A steam header at the
boiler house provides a useful centralised starting point.
It provides an extra separating function if the boiler separator is overwhelmed, and a means of
allowing the attached boilers to share the distribution system load.

Steam in from
boiler(s)

Steam out
to plant

Air
vent
Steam out
to plant

Steam distribution header

Steam trap set

Fig. 3.8.6 Steam distribution manifold

Operating pressure
The header should be designed for the boiler operating pressure and to conform to the Pressure
Systems Regulations. It is important to remember that flange standards are based on temperature
and pressure and that the allowable pressure reduces as the operating temperature increases.
For example, a PN16 rating is 16 bar at 120°C, but is only suitable for up to 13.8 bar saturated
steam (198°C).

3.8.6 The Steam and Condensate Loop

Block 3 The Boiler House Steam Headers and Off-takes Module 3.8

Diameter
The header diameter should be calculated with a maximum steam velocity of 15 m / s under
full-load conditions. Low velocity is important as it helps any entrained moisture to fall out.
Off-takes
These should always be from the top of the distribution header.
Gravity and the low velocity will ensure that any condensate falls to and drains from the bottom
of the header. This ensures that only dry steam is exported.
Steam trapping
It is important that condensate is removed from the header as soon as it forms. For this reason a
mechanical trap, for instance a float trap, is the best choice. If the header is the first trapping
point after the boiler off-takes, the condensate can contain carryover particles and it may be
useful to drain this steam trap into the boiler blowdown vessel, rather than the boiler feedtank.
Related reading:
1. The Steam and Condensate Loop, Block 11, ‘Steam Trapping’
2. The Steam and Condensate Loop, Block 10, ‘Steam Distribution’

The Steam and Condensate Loop 3.8.7

Block 3 The Boiler House Steam Headers and Off-takes Module 3.8

Questions
1. In Figure 3.8.1 which boiler works the hardest ?
a| 1 ¨
b| 2 ¨
c| 3 ¨
d| 4 ¨

2. What is one effect of an overloaded boiler ?

a| Water level rises and lock-out occurs ¨
b| Reduced steam production ¨
c| Water level drops and lock-out occurs ¨
d| Steam velocity reduces and separator efficiency drops ¨

3. Why is slow, controlled warm-up of a steam system essential ?

a| To make it easier to open the boiler main stop valve ¨
b| To minimise undue stresses and eliminate damage ¨
c| To permit separators to remove more water ¨
d| To prevent stress on the boiler ¨

4. Which of the following is the main purpose of the steam distribution manifold ?
a| It replaces the need for a separator after the boiler ¨
b| To remove air from the steam system ¨
c| To provide an extra separating function ¨
d| It is a requirement of the pressure systems regulations ¨

5. Four boilers are connected to a common header as in Figure 3.8.2.

Why is a second isolation valve after each main stop valve a recommendation ?
a| For slow opening and warm-up ¨
b| To balance the boiler loading in a multi-boiler arrangement ¨
c| In place of a check valve ¨
d| To double isolate against reverse flow ¨

6. Priming of a boiler is:

a| Getting a boiler prepared for start-up ¨
b| A reduction in boiler pressure and carryover of water ¨
c| Occurrence of excessive TDS and carryover of water ¨
d| Balancing of boilers in a multi-boiler installation ¨

Answers
1: d, 2: c, 3: b, 4: c, 5: d, 6: b

3.8.8 The Steam and Condensate Loop