Trans Chapter7

PIPENET VISION TRAINING MANUAL TRANSIENT: CHAPTER 7
PAGE 1 OF 48 REVISION 2.1, SEP 2010
PIPENET VISION TRANSIENT MODULE
CHAPTER 7
STEAM HAMMER IN MAIN STEAM SYSTEM
1. Introduction
In addition to being able to accurately predict liquid flow, the PIPENET VISION Transient
Module can realistically model the steam hammer, and also estimate the magnitude of
dynamic forces in the pipeline. The steam hammer normally occurs when one or more
valves suddenly close or open. In a power plant, the steam hammer could be an inevitable
phenomenon during turbine trip, since valves (e.g., main steam valves) must be closed
very quickly to protect the turbine from further damage.
In this chapter, we model and analyse the steam hammer in the scenario of a turbine trip.
Also, we discuss the dynamic force, and how to model boiler valves and safety/by-pass
valves.
2. The Network
The main steam system is not a complex system. However, its boundary conditions (i.e.,
specifications) should be considered carefully. The figure below illustrates the main steam
system of a 600MW supercritical unit and the parameters at steady state. The system
parameters are as follows.
Unit type: 600MW supercritical,

System: Main steam system,
Pressure: 242 bar-a (turbine side),
Temperature: 569 ºC,
Boiler capacity: 1900 tons/hr,
Pipe material: P91,
Pipe size: 420.7mmIDX579.7mmOD (main pipe),
306.4mmIDX425.4mmOD (branch to turbine/boiler),
274.6mmIDX383.6mmOD (branch to HP by-pass valve),
Main steam valve: 2257 [m3/hr, bar] (see Appendix 1),
Bypass valve: 132 [m3/hr, bar] (see Appendix 1),
Safety (relief) valve: 219 [m3/hr, bar] (see Appendix 1).
3. Model initialization
3.1 Module Options
When the PIPENET Vision Transient Module is started, the first screen that appears is
shown below. The user has the choice of the Standard or Spray Options. The Standard
Option is designed for general industry applications, in which the built-in pipe library covers
the most popular pipe schedules (such as ANSI, DIN and JIS standards). The library of
built-in fittings is based on the CRANE Standard. The Spray Option is specially designed
for the fire protection industry, in which the built-in pipe library is limited to a few schedules
that are relevant to the fire protection industry. The built-in fittings library is from the NFPA
rules, and the user cannot extend it by building a user-defined library. The Hazen Williams
equation is available for calculating the frictional pressure loss. The user can create a
user-defined pipe library in both the Standard and Spray Options. Here, the Standard
Option is selected for modelling the steam hammer in the main steam system.
3.2 Title
For the current network, the PIPENET VISION Menu Style is to be used (as opposed to
the Windows Menu Style), which can be chosen using the Window Menu in the Transient
Module. Select Init | Title, and then input a description of the problem. The input title
appears in the header of the program, and is written to the calculation report.
3.3 Transient Options
The Module Options Window (obtained from Init | Module options) contains the
simulation times, time step options, ambient conditions, hydraulic force options, pressure
model options, default parameters and cavitation model options. There are two options for
the force in PIPENET VISION: total force and dynamic force. The total force is an absolute
force and the dynamic force is a relative force, which represents the difference of the
current force from the force at a certain base time.
3.4 Units
A comprehensive range of units is available in PIPENET VISION (which can automatically

convert the input data into new units if the units system changes). The button named
“Save as defaults” can be used to save the current units as the defaults units, in which
case PIPENET VISION will always default to these units when a new model is created.
Also, the display precision can be changed here for every unit. The actual units used in the
current network are shown below.
Length m Mass kg Thermal conductivity W/(m.K)

Diameter mm Mass rate kg/s Heat capacity J/(kg.K)
Velocity m/s Torque Nm Young’s modulus GPa
2
Temperature Celsius Inertia kg.m Pressure Bar G
3
Density kg/m Force N Flow type Mass
3
Viscosity Pa.s Volume m Flow rate kg/hr
Time secs Surface tension N/m
3.5 Fluid Properties
The fluid properties are set in the Fluid Window or API Fluid Window. In the current
problem, the built-in calculator for water-steam is used to calculate the steam properties.
The average pressure and temperature are estimated to be 248.9868 barg and 569 ºC
respectively.
3.6 Pipe Types
The user can add any built-in or user-defined pipe schedules to the current network in the
Pipe Types Window (Init | Pipe type). If the desired pipes are not included in the built-in
library, a user-defined pipe schedule must be created in the pipe library beforehand.
4. Library Data
4.1 Pipe Schedule Data
The pipe material is P91 and the relative properties at the working conditions (of 569 ºC
and 248.9868 barg) are listed below.
Pipe roughness = 0.457 mm,

Poisson’s Ratio = 0.292,
Young’s Modulus of elasticity = 213.08 Gpa.
Nominal Size (mm) Internal Diameter (mm) External Diameter (mm)

300 274.6 383.6
350 306.4 425.4
450 420.7 579.7
4.2 Pipe Fitting Data
The network contains a Y-type tee, which is a non-standard fitting in the CRANE standard.
Therefore, a new fitting is to be defined in the user-defined fittings library (which is
accessed via Libraries | Fittings).
We have now finished inputting the initial settings for the problem, and have built several
user-defined libraries. It is now time to build the model for the main steam network.
5. Building the Network
5.1 The Network
The network in Section 2 represents a complete main steam system, but not a complete
hydraulic model. The boiler is actually a giant device with a complex pipe network. Any
fluctuation aroused in the main steam system will propagate upwards to the interior of the
boiler and reflect back. Therefore, it is impossible to obtain a constant flow rate or pressure
at the outlet of the boiler during a simulation. The calculated results are not accurate,
especially those at the boiler side. However, the actual pipe system in the boiler is too
complex to model exactly, and so it must be properly simplified. Generally, the boiler is
simplified as a dummy pipe, in order to consider its effect on the wave propagation. The
boundary conditions must take into account the structure characteristics of the boiler.
• Drum boiler: The pressure of the drum changes slightly in a short time after the turbine
trip, owing to a mass of steam in the drum. The drum can, therefore, be assigned a
constant pressure specification. The diameter of the dummy pipe is the equivalent
diameter of the tube bundle of the superheater or the full capacity pipe of the main
steam system (if the required information of the boiler is not available). The length is
the total length of the superheater from the boiler outlet to the drum.
• Cocurrent boiler: The heating capacity of the boiler cannot decrease dramatically after
a turbine trip, which makes the steam flowrate almost constant during a simulation. The
diameter of the dummy pipe is the equivalent diameter of the tube bundle of the
superheater or the full capacity pipe of the main steam system (if the required
information of the boiler is unknown). The length can be approximated as the distance
between the boiler outlet and the transition point at which the intermitted flow becomes
the dominated flow pattern (since most of the wave will reflect back there).
A 600MW supercritical unit is studied in the following example. A supercritical boiler must
be a cocurrent boiler, so that the boiler can be represented by a constant flow
specification. The DN450 main steam pipe is used as the equivalent dummy pipe to model
the tube bundles of the superheater. The length is assumed to be 250 metres (see the
schematic below).
5.2 Pipe Data
Label Input Output Type Diameter Length Elevation Roughness Additional Section Type
Node Node (mm) (m) (m) (mm) K-factor
1 10 2 P91 350 5.3 5.3 0.457 0 Constant Gradient
2 11 10 P91 350 12.6 0 0.457 0 Constant Gradient
4 7 5 P91 350 5.3 5.3 0.457 0 Constant Gradient
5 8 7 P91 350 8.6 0 0.457 0.092 Constant Gradient
9 14 12 P91 450 18.5 -18.5 0.457 0 Constant Gradient
27 32 28 P91 450 250 0 0.457 10 Constant Gradient
Notes
• Pipe 5 is assigned an additional K-factor of 0.092 to represent a 45º bend (r/d = 1.5)
between Pipe 5 and Pipe 6, since this fitting is not a standard CRANE fitting.
• The dummy pipe (Pipe 27) is assigned an additional K-factor of 10 to represent the
local pressure loss coefficient in the superheater.
5.3 Valve Data
If the valve manufacturer does not provide the Cv or K-factor values, Appendix 1 contains a
method to estimate their values. However, it is preferable to obtain these values from the
manufacturer. In this problem, it is assumed that all of the modelled valves have linear
characteristics. The valve data is, therefore, input through the properties window (rather
than the library) because only the flow coefficient (Cv) at a fully open valve is known (see
Appendix 1).
Name Label Input Output Information Type Flow coefficient

3
Node Node Node [m /hr, bar]
Main steam valve 1 1 2 3 Flow coefficient 2257
Main steam valve 2 4 5 6 Flow coefficient 2257
HP by-pass valve 3 29 30 31 Flow coefficient 132
5.4 Safety Valve Data
As is the case with the valves listed above, all the safety valves are assumed to have
linear characteristics, and the flow coefficient (Cv) for a fully open valve is known (see
Appendix 1). In addition, the safety valves have a 3-bar hysteresis.
Name Label Input Output Flow Set Wide Fully Closed

Node Node Coefficient Pressure Open Pressure
3
[m /hr, bar] (Bar G) Pressure (Bar G)
(Bar G)
Boiler safety valve 1 23 24 219 270 275 267
Boiler safety valve 2 33 25 219 270 275 267
5.5 Boundary Conditions
The boundary conditions at the turbine side can be considered to be constant pressure
specifications, before the main steam valves are fully closed. As mentioned above, a
supercritical boiler can be treated as a constant flow specification for a simulation lasting a
few seconds. The HP by-pass valve and the safety valves will work at critical conditions
once they are opened. Therefore, the outlet pressures must be assigned as 0 bara
regardless of their actual pressures, to agree with the valve models that were originally
developed for subsonic flow in PIPENET VISION. (Please refer to Appendix 1 for an
explanation.)
Name Node Specification Type Specification

MPa-a tons/hr
Turbine side 1 Pressure 24.2
Turbine side 4 Pressure 24.2
Boiler safety valve outlet 24 Pressure 0.0
Boiler safety valve outlet 25 Pressure 0.0
HP by-pass valve outlet 30 Pressure 0.0
Boiler side 28 Flowrate 1900
5.6 Dynamic Force Definition
There are two types of force in PIPENET VISION: simple force and complex force. A
simple force is a one-dimensional force, and all components in the control volume for the
force must share the same axis. A complex force is a three-dimensional force. It is
normally used to study the effect of local hydraulic forces on a piece of fitting for local
stress analysis. Normally, engineers are only interested in simple forces for studying the
effect of dynamic forces on the pipeline and the supports. Therefore, two simple forces are
defined here for illustration purposes. They are located at the inlet of the turbine and at a
long a vertical pipe before the boiler.
Force 1: Force in a single pipe (Pipe 14).

Force 2: Force between Pipes 3 and 8, including a reducer and tee.

5.7 Output Selection
A transient simulation can potentially produce a very large number of results. For this
reason, PIPENET VISION allows the user to control the graphical or tabular output to limit
the size of the calculation report (.out) and results file (.res). The output results are
selected in the Data Window or from the shortcut menu (which is displayed by right
clicking a component).
Tabular output can be selected from only a data window:

The graphical output is selected either from a data window or via the shortcut menu. Note
that the colour of the component in the Schematic Window changes to green when results
for the component have been selected.
The time intervals for the output (which are specified via Calculation | Options… |
Output) cannot be smaller than the calculation time step. Information relating to the force
file, which is the interface between other stress analysis programs (such as CAESAR II), is
specified here. The interface between PIPENET and CAESAR II is introduced in
Appendix 2.
6. The Scenarios
6.1 Scenario 1: Steady State
It is standard practice to check the calculation results at steady state, to ensure the
correctness and precision of the model before carrying out further simulations in transient
conditions. In this scenario, the main steam valves are kept open and the by-pass valve is
always closed.
The pressure at the outlet of the boiler is checked. The pressure loss in the main steam
system is about 13.4 bar; i.e., 5.2% of the main steam pressure.
6.2 Scenario 2: Turbine Trip With By-pass Valve Closure
In this scenario, the main steam valves are quickly closed in 0.2 seconds after the turbine
trip. The by-pass valve is kept closed, and the safety valves automatically open shortly
afterwards, to protect the main steam system from overpressure.
After the main steam valves close, the maximum pressure of the main steam system can
reach around 280 barg at the turbine side.
After the main steam valves close, the safety valves can control the maximum pressure to
be under 275 barg on the boiler side. The safety valves become fully opened, but finally
settle at around 95% opening.
In this scenario, the maximum dynamic force is about 4.3 KN/m.
6.3 Scenario 3: Turbine Trip With Bypass Valve Opening
The bypass valve is always closed in Scenario 2. If the bypass valve could discharge (and
so function as a pressure relief valve), it would quickly open soon after the turbine trip, to
release pressure and reclaim part steam. In this scenario, the bypass valve starts to open
2 seconds later, since the main steam valves are closed.
After the main steam valves close, the maximum pressure in the main steam system can
reach over 280 barg on the turbine side.
After the main steam valves close, the safety valves can restrict the maximum pressure to
be under 275 barg on the boiler side. The safety valves become fully open, but finally
settle at about 66% of the fully open state.
After the valve is fully open, the flow rate of the by-pass valve is about 600 tons/hr. The
design capacity is 570 tons/hr when the inlet pressure is 250 bara. However, the actual
inlet pressure increases to 272 bara after the turbine trips.
The maximum dynamic force is about 4.3 KN/m in this scenario.

Appendix 1. How to Calculate the Valve Factor
1. Introduction
The values of both Cv and Kv are used to specify the capacity of control valves. They are
the same factor, but in different units. Cv is based on the Imperial Units System, and is
defined as the flow of water through a valve at 60 ºF in US gallons per minute at a
pressure drop of 1 psi. Its units are [US gallon/min, psi]. Kv, on the other hand, is based
on the SI System, and is defined as the flow of water through a valve at 20 ºC in cubic
metres per hour at a pressure drop of 1 bar. Its unit is [m3/hr, bar].
The relationship between Cv and Kv is approximately
Cv = 1.16 Kv.
Note that a more accurate relationship between Cv and Kv involves a factor of 1.156099 (in
place of 1.16). If the units for Cv or Kv are not available from the manufacturer, the default
units (i.e., [US gallon/min, psi] for Cv and [m3/hr, bar] for Kv) should be used. However, it is
advisable to ask the manufacturer to verify the units.
Conversion between Cv and Kv values can be obtained automatically in PIPENET VISION

by changing the units system. The following example illustrates how to convert from Kv to
Cv.
1. Set the units for Kv (via Init | Units). For example, choose “bar Abs” for pressure and
“m3/hr” for flow rate.
2. Assign a value of 1 [m3/hr, bar] to the flow coefficient (i.e., Kv).
3. Change the model units to be the required units for Cv; i.e., “psi Abs” for pressure and
“US gallon/min” for flow rate.
4. The value of the flow coefficient, Cv, is displayed in the new unit system; namely,
approximately 1.16 [US gallon/min, psi].
Please note that the Kv and K-factor are different. The K-factor is a dimensionless factor
that signifies the local friction coefficient. It must be used in combination with the valve port
area to calculate the pressure drop across a valve.
2. How to Calculate Cv (or Kv)
To simulate the behavior of a valve in a hydrodynamic analysis in PIPENET VISION, the

user requires either (a) the Cv value or (b) both the K-factor and the valve port area.
However, sometimes the manufacturer can provide information such as the inlet/outlet
pressures, temperatures and flow rates, rather than supply Cv or the K-factor directly. In
this case, therefore, the user must deduce Cv or the K-factor from known parameters.
The method for calculating Cv or Kv is illustrated below, and is suitable for liquid, saturated
steam, superheated steam and gas. The permitted pressure drop includes a wide range,
up to supercritical flow. When fluid reaches the critical (sonic) velocity in a valve (i.e., when
the outlet pressure is less than half of the inlet pressure), any disturbance that is present in
the downstream flow cannot spread to the upstream flow. In this case, a complex network
may be separated into two simpler sub-networks in a hydrodynamic calculation. This is a
very importance point, which can simplify the model and make the problem easier to solve.
3. Example 1: Main Steam Valve
Suppose that the specifications are as follows.
Flow rate: 950 tons/hr,

Outlet pressure: 242 bar-a ,
Pressure drop: 2.42 bar,
Temperature: 569 ˚C,
Density: 72.86 m3/kg.
Since the steam is superheated, and P2 > P1/2,

G 950 ×1000
Kv = = = 2257 m 3 / hr , bar [ ]
31.7 ∆P × ρ 31.7 × 2.42 × 72.86
4. Example 2: Bypass Valve
Suppose that the follow specifications apply.
Flow rate: 570 tons/hr,

Inlet pressure: 250 bar-a,
Outlet pressure: 4.81 bar-a,
Inlet temperature: 569 ˚C,
Density: 34.59 m3/kg (under the inlet temperature and half of the inlet
pressure).
Since the steam is superheated, and P2 < P1/2,
G 570 ×1000
Kv = = = 274 m 3 / hr , bar [ ]
22.4 ρP1 22.4 × 34.59 × 250
However, the above result cannot be used in PIPENET VISION directly, because a
different equation for Kv is used there; namely, one in which it is assumed that the liquid is
the default fluid. The equation in PIPENET VISION is
Q1 G
Kv ' = =
ρ 0 (P1 − P2 ) 1000 × ρ1 (P1 − P2 )
ρ1
As mentioned above, when the pressure drop across the valve exceeds half of the inlet
pressure, the flow state at the upstream end of the valve is not affected by the downstream
flow. Therefore, the network located downstream of the valve can be neglected in the
calculation. The outlet pressure, P2, can be assumed to be 0 bar-a, regardless of the
actual outlet pressure. The equation in PIPENET VISION can then be simplified to
G ρ
Kv ' = = Kv
22.4 2 ρ1 P1 2 ρ1
where
ρ is the density under P1/2 and T1,

ρ1 is the density under P1 and T1.
Consider a supercritical steam system, in which P1 = 250 bar-a, T1 = 569 ºC,

ρ = 34.59 kg/m3, ρ1 = 75.27 kg/m3. The relationship between Kv’ and Kv is
Kv’= 0.48 Kv.
For other steam systems, with a lower pressure, such as a reheat system,
ρ1 ≈ 2 ρ ,
Kv’= 0.5 Kv.
In our case, the calculated value of Kv for the bypass valve is 274 [m3/hr, bar]. The
converted Kv value used in PIPENET VISION should be 132 [m3/hr, bar]. However, the
outlet pressure of the valve must be specified as 0 bar-a. Similarly, values for the safety
valves (2x50% capacity) can be calculated using the above principle, with Kv as
219 [m3/hr, bar] in PIPENET VISION.
5. Valves in Parallel or Series
If several valves are assembled in parallel, the valves can be combined into one equivalent
valve. The total equivalent value of Kv is equal to the sum of the individual Kv values; i.e.,
Kvtotal = Kv1 + Kv2 + ... + Kvn

This expression is useful for simplifying a safety (pressure relief) valve system. The
assembly of a series of valves is used much less frequently than the parallel case.
However, in this case, the equivalent Kv can be calculated using
1 1 1 1
2
= + + K +
Kv total Kv12 Kv 22 Kv n2
6. How to Estimate the K-factor Based on Valve Type and Size
The K-factor of an unknown valve can be estimated by referring to a typical valve with the
same type and size. The typical valves have been included in PIPENET VISION, based on
the standards used. The K-factor is a function of the valve type and size and can be
obtained by browsing the Fittings Tab of the Properties Window for the pipe, as shown
below. However, this is an approximate method, which may result in a considerable error.
Appendix 2. How to Use the Interface Between Caesar II and

PIPENET
Step 1
Select the PIPENET/C2 interface command.

Step 2
Click on “Browse” and locate the .frc file.
Note that one node number in the C2 model must be specified for each force component in
.frc file.
Step 3
Accept the following prompt, and then locate the C2 input file. Note that 5 DLF files are
created automatically.
Step 4
Open the Dynamic Analysis Module. Note that there are 5 DLFs at the end of the list.
Step 5
Specify the direction of the applied forces shown below, using direction cosines.
Step 6
Use the same directions for the Spectrum Load Cases.
Step 7
Change the Frequency Array Spaces to 500 for this particular job, and increase the
Memory Allocated to 12Mb. Because there are too many eigenpairs for this problem, the
eigensolver needs more space. You may decrease the Frequency Cut-off to lower values
for a reduced solution time, but some modes are ignored.
Step 8
There are stress failures arising from OCC load case # 5, which was %81 in static results.

Trans Chapter7

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Trans Chapter7

Uploaded by

Copyright:

Available Formats

PIPENET VISION TRAINING MANUAL TRANSIENT: CHAPTER 7

PAGE 1 OF 48 REVISION 2.1, SEP 2010

PIPENET VISION TRANSIENT MODULE

STEAM HAMMER IN MAIN STEAM SYSTEM

Unit type: 600MW supercritical,

3.1 Module Options

3.3 Transient Options

A comprehensive range of units is available in PIPENET VISION (which can automatically

Length m Mass kg Thermal conductivity W/(m.K)

3.5 Fluid Properties

3.6 Pipe Types

4.1 Pipe Schedule Data

Pipe roughness = 0.457 mm,

Nominal Size (mm) Internal Diameter (mm) External Diameter (mm)

4.2 Pipe Fitting Data

5. Building the Network

5.1 The Network

5.2 Pipe Data

5.3 Valve Data

Name Label Input Output Information Type Flow coefficient

5.4 Safety Valve Data

Name Label Input Output Flow Set Wide Fully Closed

5.5 Boundary Conditions

Name Node Specification Type Specification

5.6 Dynamic Force Definition

Force 1: Force in a single pipe (Pipe 14).

Force 2: Force between Pipes 3 and 8, including a reducer and tee.

5.7 Output Selection

Tabular output can be selected from only a data window:

6.1 Scenario 1: Steady State

6.2 Scenario 2: Turbine Trip With By-pass Valve Closure

In this scenario, the maximum dynamic force is about 4.3 KN/m.

6.3 Scenario 3: Turbine Trip With Bypass Valve Opening

The maximum dynamic force is about 4.3 KN/m in this scenario.

Appendix 1. How to Calculate the Valve Factor

The relationship between Cv and Kv is approximately

Conversion between Cv and Kv values can be obtained automatically in PIPENET VISION

2. Assign a value of 1 [m3/hr, bar] to the flow coefficient (i.e., Kv).

2. How to Calculate Cv (or Kv)

To simulate the behavior of a valve in a hydrodynamic analysis in PIPENET VISION, the

3. Example 1: Main Steam Valve

Suppose that the specifications are as follows.

Flow rate: 950 tons/hr,

Since the steam is superheated, and P2 > P1/2,

4. Example 2: Bypass Valve

Suppose that the follow specifications apply.

Flow rate: 570 tons/hr,

Since the steam is superheated, and P2 < P1/2,

ρ is the density under P1/2 and T1,

Consider a supercritical steam system, in which P1 = 250 bar-a, T1 = 569 ºC,

Kv’= 0.48 Kv.

5. Valves in Parallel or Series

Kvtotal = Kv1 + Kv2 + ... + Kvn

6. How to Estimate the K-factor Based on Valve Type and Size

Appendix 2. How to Use the Interface Between Caesar II and

Select the PIPENET/C2 interface command.

Click on “Browse” and locate the .frc file.

Use the same directions for the Spectrum Load Cases.

You might also like