Block 10 Steam Distribution

Steam Mains and Drainage Module 10.3

Module 10.3
Steam Mains and Drainage

The Steam and Condensate Loop

10.3.1

Block 10 Steam Distribution

Steam Mains and Drainage Module 10.3

Steam Mains and Drainage

Throughout the length of a hot steam main, an amount of heat will be transferred to the environment, and this will depend on the parameters identified in Block 2 - Steam Engineering and Heat Transfer, and brought together in Equation 2.5.1.

Q = kA

Equation 2.5.1

Where: Q = Heat transferred per unit time (W) k = Thermal conductivity of the material (W /m K or W /m C) A = Heat transfer area (m ) T = Temperature difference across the material (K or C) = Material thickness (m) With steam systems, this loss of energy represents inefficiency, and thus pipes are insulated to limit these losses. Whatever the quality or thickness of insulation, there will always be a level of heat loss, and this will cause steam to condense along the length of the main. The effect of insulation is discussed in Module 10.5. This Module will concentrate on disposal of the inevitable condensate, which, unless removed, will accumulate and lead to problems such as corrosion, erosion, and waterhammer. In addition, the steam will become wet as it picks up water droplets, which reduces its heat transfer potential. If water is allowed to accumulate, the overall effective cross sectional area of the pipe is reduced, and steam velocity can increase above the recommended limits.

Piping layout
The subject of drainage from steam lines is covered in the UK British Standard BS 806:1993, Section 4.12. BS 806 states that, whenever possible, the main should be installed with a fall of not less than 1:100 (1 m fall for every 100 m run), in the direction of the steam flow. This slope will ensure that gravity, as well as the flow of steam, will assist in moving the condensate towards drain points where the condensate may be safely and effectively removed (See Figure 10.3.1).
30 - 50 metre intervals
Gradient 1:100 Gradient 1:100

Steam Trap set

Steam

Trap set

Trap set

Condensate Condensate Condensate

Fig. 10.3.1 Typical steam main installation

Drain points

The drain point must ensure that the condensate can reach the steam trap. Careful consideration must therefore be given to the design and location of drain points. Consideration must also be given to condensate remaining in a steam main at shutdown, when steam flow ceases. Gravity will ensure that the water (condensate) will run along sloping pipework and collect at low points in the system. Steam traps should therefore be fitted to these low points. 10.3.2
The Steam and Condensate Loop

Block 10 Steam Distribution

Steam Mains and Drainage Module 10.3

The amount of condensate formed in a large steam main under start-up conditions is sufficient to require the provision of drain points at intervals of 30 m to 50 m, as well as natural low points such as at the bottom of rising pipework. In normal operation, steam may flow along the main at speeds of up to 145 km/h, dragging condensate along with it. Figure 10.3.2 shows a 15 mm drain pipe connected directly to the bottom of a main.
Steam Flow

Condensate Steam trap set Fig. 10.3.2 Trap pocket too small

Although the 15 mm pipe has sufficient capacity, it is unlikely to capture much of the condensate moving along the main at high speed. This arrangement will be ineffective. A more reliable solution for the removal of condensate is shown in Figure 10.3.3. The trap line should be at least 25 to 30 mm from the bottom of the pocket for steam mains up to 100 mm, and at least 50 mm for larger mains. This allows a space below for any dirt and scale to settle.
Steam Flow

Pocket Steam trap set Fig. 10.3.3 Trap pocket properly sized

Condensate

The bottom of the pocket may be fitted with a removable flange or blowdown valve for cleaning purposes. Recommended drain pocket dimensions are shown in Table 10.3.1 and in Figure 10.3.4.
Table 10.3.1 Recomended drain pocket dimensions Mains diameter - D Pocket diameter - d1 Up to 100 mm nb d1 = D 125 - 200 mm nb d1 = 100 mm 250 mm and above d1 D / 2 Pocket depth - d2 Minimum d2 = 100 mm Minimum d2 = 150 mm Minimum d2 = D

Steam

D d2

Steam main d1

Float trap with in-built sensor Fig. 10.3.4 Condensate return

The Steam and Condensate Loop

10.3.3

Block 10 Steam Distribution

Steam Mains and Drainage Module 10.3

Waterhammer and its effects

Waterhammer is the noise caused by slugs of condensate colliding at high velocity into pipework fittings, plant, and equipment. This has a number of implications:
o

Because the condensate velocity is higher than normal, the dissipation of kinetic energy is higher than would normally be expected. Water is dense and incompressible, so the cushioning effect experienced when gases encounter obstructions is absent. The energy in the water is dissipated against the obstructions in the piping system such as valves and fittings.
Steam Condensate Steam Slug Steam Fig. 10.3.5 Formation of a solid slug of water

Indications of waterhammer include a banging noise, and perhaps movement of the pipe. In severe cases, waterhammer may fracture pipeline equipment with almost explosive effect, with consequent loss of live steam at the fracture, leading to an extremely hazardous situation. Good engineering design, installation and maintenance will avoid waterhammer; this is far better practice than attempting to contain it by choice of materials and pressure ratings of equipment. Commonly, sources of waterhammer occur at the low points in the pipework (See Figure 10.3.6). Such areas are due to:
o o

Sagging in the line, perhaps due to failure of supports. Incorrect use of concentric reducers (see Figure 10.3.7) - Always use eccentric reducers with the flat at the bottom. Incorrect strainer installation - They should be fitted with the basket on the side. Inadequate drainage of steam lines. Incorrect operation - Opening valves too quickly at start-up when pipes are cold.
Steam Concentric reducer Condensate Steam Riser

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Steam Condensate Strainer with hanging basket Fig. 10.3.6 Potential sources of waterhammer

Condensate

10.3.4

The Steam and Condensate Loop

Block 10 Steam Distribution

Steam Mains and Drainage Module 10.3

Eccentric reducer
Correct Steam

Condensate Incorrect

Steam

Condensate

Concentric reducer

Fig. 10.3.7 Eccentric and concentric pipe reducers

To summarise, the possibility of waterhammer is minimised by:

o

Installing steam lines with a gradual fall in the direction of flow, and with drain points installed at regular intervals and at low points. Installing check valves after all steam traps which would otherwise allow condensate to run back into the steam line or plant during shutdown. Opening isolation valves slowly to allow any condensate which may be lying in the system to flow gently through the drain traps, before it is picked up by high velocity steam. This is especially important at start-up.

Branch lines

Steam

Steam main

Steam

Branch line

Steam Fig. 10.3.8 Branch line

Branch lines are normally much shorter than steam mains. As a general rule, therefore, provided the branch line is not more than 10 metres in length, and the pressure in the main is adequate, it is possible to size the pipe on a velocity of 25 to 40 m/s, and not to worry about the pressure drop. Table 10.2.4 Saturated steam pipeline capacities for different velocities in Module 10.2 will prove useful in this exercise.

The Steam and Condensate Loop

10.3.5

Block 10 Steam Distribution

Steam Mains and Drainage Module 10.3

Branch line connections

Branch line connections taken from the top of the main carry the driest steam (Figure 10.3.8). If connections are taken from the side, or even worse from the bottom (as in Figure 10.3.9 (a)), they can accept the condensate and debris from the steam main. The result is very wet and dirty steam reaching the equipment, which will affect performance in both the short and long term. The valve in Figure 10.3.9 (b) should be positioned as near to the off-take as possible to minimise condensate lying in the branch line, if the plant is likely to be shutdown for any extended periods.

(a) Incorrect

(b) Correct

Fig. 10.3.9 Steam off-take

Drop leg
Low points will also occur in branch lines. The most common is a drop leg close to an isolating valve or a control valve (Figure 10.3.10). Condensate can accumulate on the upstream side of the closed valve, and then be propelled forward with the steam when the valve opens again consequently a drain point with a steam trap set is good practice just prior to the strainer and control valve.
Steam Drop leg Isolation valve Strainer Control valve Unit heater Isolation valve Isolation valve

Trap set

Trap set Condensate Fig. 10.3.10 Diagram of a drop leg supplying a unit heater Condensate

10.3.6

The Steam and Condensate Loop

Block 10 Steam Distribution

Steam Mains and Drainage Module 10.3

Rising ground and drainage

There are many occasions when a steam main must run across rising ground, or applications where the contours of the site make it impractical to lay the pipe with the 1:100 fall proposed earlier. In these situations, the condensate must be encouraged to run downhill and against the steam flow. Good practice is to size the pipe on a low steam velocity of not more than 15 m /s, to run the line at a slope of no less than 1:40, and install the drain points at not more than 15 metre intervals (see Figure 10.3.11). The objective is to prevent the condensate film on the bottom of the pipe increasing in thickness to the point where droplets can be picked up by the steam flow.
Increase in pipe diameter Fall 1:40 Fall 30 m/s
15 m 15 m

Steam velocity 30 m/s

1:100 Fall

Steam velocity 15 m/s

30 - 50 m

Fig. 10.3.11 Reverse gradient on steam main

Steam separators
Modern packaged steam boilers have a large evaporating capacity for their size and have limited capacity to cope with rapidly changing loads. In addition, as discussed in Block 3 The Boiler House, other circumstances, such as . . .
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Incorrect chemical feedwater treatment and /or TDS control Transient peak loads in other parts of the plant

. . . can cause priming and carryover of boiler water into the steam mains. Separators, as shown by the cut section in Figure 10.3.12, may be installed to remove this water.
Air and incondensable gases vented

Dry steam out

Wet steam in

Moisture to trap set Fig. 10.3.12 Cut section through a separator

The Steam and Condensate Loop

10.3.7

Block 10 Steam Distribution

Steam Mains and Drainage Module 10.3

As a general rule, providing the velocities in the pipework are within reasonable limits, separators will be line sized. (Separators are discussed in detail in Module 12.5) A separator will remove both droplets of water from pipe walls and suspended mist entrained in the steam itself. The presence and effect of waterhammer can be eradicated by fitting a separator in a steam main, and can often be less expensive than increasing the pipe size and fabricating drain pockets. A separator is recommended before control valves and flowmeters. It is also wise to fit a separator where a steam main enters a building from outside. This will ensure that any condensate produced in the external distribution system is removed and the building always receives dry steam. This is equally important where steam usage in the building is monitored and charged for.

Strainers
When new pipework is installed, it is not uncommon for fragments of casting sand, packing, jointing, swarf, welding rods and even nuts and bolts to be accidentally deposited inside the pipe. In the case of older pipework, there will be rust, and in hard water districts, a carbonate deposit. Occasionally, pieces will break loose and pass along the pipework with the steam to rest inside a piece of steam using equipment. This may, for example, prevent a valve from opening / closing correctly. Steam using equipment may also suffer permanent damage through wiredrawing - the cutting action of high velocity steam and water passing through a partly open valve. Once wiredrawing has occurred, the valve will never give a tight shut-off, even if the dirt is removed. It is therefore wise to fit a line-size strainer in front of every steam trap, flowmeter, reducing valve and regulating valve. The illustration shown in Figure 10.3.13 shows a cut section through a typical strainer.

C B

Fig. 10.3.13 Cut section through a Y-type strainer.

Steam flows from the inlet A through the perforated screen B to the outlet C. While steam and water will pass readily through the screen, dirt cannot. The cap D, can be removed, allowing the screen to be withdrawn and cleaned at regular intervals. A blowdown valve can also be fitted to cap D to facilitate regular cleaning. Strainers can however, be a source of wet steam as previously mentioned. To avoid this situation, strainers should always be installed in steam lines with their baskets to the side. Strainers and screen details are discussed in Module 12.4. 10.3.8
The Steam and Condensate Loop

Block 10 Steam Distribution

Steam Mains and Drainage Module 10.3

How to drain steam mains

Steam traps are the most effective and efficient method of draining condensate from a steam distribution system. The steam traps selected must suit the system in terms of:
o o o

Pressure rating Capacity Suitability

Pressure rating Pressure rating is easily dealt with; the maximum possible working pressure at the steam trap will either be known or should be established. Capacity Capacity, that is, the quantity of condensate to be discharged, which needs to be divided into two categories; warm-up load and running load. Warm-up load - In the first instance, the pipework needs to be brought up to operating temperature. This can be determined by calculation, knowing the mass and specific heat of the pipework and fittings. Alternatively, Table 10.3.2 may be used.
o

The table shows the amount of condensate generated when bringing 50 m of steam main up to working temperature; 50 m being the maximum recommended distance between trapping points. The values shown are in kilograms. To determine the average condensing rate, the time taken for the process must be considered. For example, if the warm-up process required 50 kg of steam, and was to take 20 minutes, then the average condensing rate would be: 60 minutes Average condensing rate = x 50 kg 20 minutes Average condensing rate = 150 kg h When using these capacities to size a steam trap, it is worth remembering that the initial pressure in the main will be little more than atmospheric when the warm-up process begins. However, the condensate loads will still generally be well within the capacity of a DN15 low capacity steam trap. Only in rare applications at very high pressures (above 70 bar g), combined with large pipe sizes, will greater trap capacity be needed.

Running load - Once the steam main is up to operating temperature, the rate of condensation is mainly a function of the pipe size and the quality and thickness of the insulation. Again, with sufficient data, the heat losses can be determined. Alternatively Table 10.3.3 can be used which shows typical amounts of steam condensed per 50 m of steam main at various pressures. The average condensing rate is determined in the same way as that shown above for warm-up load.

The Steam and Condensate Loop

10.3.9

Block 10 Steam Distribution

Steam Mains and Drainage Module 10.3

Table 10.3.2 Amount of steam condensed to warm-up 50 m of schedule 40 pipe (kg) Note: Figures are based on an ambient temperature of 20C, and an insulation efficiency of 80% Steam -18C Steam main size (mm) pressure correction bar g 50 65 80 100 125 150 200 250 300 350 400 450 500 600 factor
1 2 3 4 5 6 7 8 9 10 12 14 16 18 20 25 30 40 50 60 70 80 90 100 120 5 6 7 8 8 9 9 9 10 10 10 11 12 17 17 19 21 22 24 27 29 32 34 35 42 9 10 11 12 13 13 14 14 15 16 17 17 19 23 26 29 32 34 37 41 44 49 51 54 64 11 13 14 16 17 18 18 19 20 20 22 23 24 31 35 39 41 46 50 54 59 65 69 72 86 16 19 20 22 24 25 26 27 28 29 31 32 35 45 51 56 62 67 73 79 86 95 100 106 126 22 25 25 30 33 34 35 37 38 40 42 44 47 62 71 78 86 93 101 135 156 172 181 190 227 28 33 36 39 42 43 45 47 50 51 54 57 61 84 97 108 117 127 139 181 208 232 245 257 305 44 49 54 59 63 66 68 71 74 77 84 85 91 127 148 164 179 194 212 305 346 386 409 427 508 60 69 79 83 70 93 97 101 105 109 115 120 128 187 220 243 265 287 214 445 510 568 598 628 748 79 94 123 92 108 142 101 120 156 110 131 170 119 142 185 124 147 198 128 151 197 134 158 207 139 164 216 144 171 224 152 180 236 160 189 247 172 203 265 355 305 393 302 362 465 333 400 533 364 437 571 395 473 608 432 518 665 626 752 960 717 861 1 100 800 960 1 220 842 1 011 1 288 884 1 062 1 355 1 052 1 265 1 610 155 179 197 215 233 242 250 261 272 282 298 311 334 492 582 642 702 762 834 1 218 1 396 1 550 1 635 1 720 2 050 182 210 232 254 275 285 294 307 320 332 350 366 393 596 712 786 859 834 1 020 1 480 1 694 1 890 1 990 2 690 2 490 254 296 324 353 382 396 410 428 436 463 488 510 548 708 806 978 1 150 1 322 1 450 2 140 2 455 2 730 2 880 3 030 3 600 1.39 1.35 1.32 1.29 1.28 1.27 1.26 1.25 1.24 1.24 1.23 1.22 1.21 1.21 1.20 1.19 1.18 1.16 1.15 1.15 1.15 1.14 1.14 1.14 1.13

Table 10.3.3 Amount of steam condensed during operation of 50 m of schedule 40 pipe (kg) Note: Figures are based on an ambient temperature of 20C, and an insulation efficiency of 80% Steam -18C Steam main size (mm) pressure correction bar g 50 65 80 100 125 150 200 250 300 350 400 450 500 600 factor
1 2 3 4 5 6 7 8 9 10 12 14 16 18 20 25 30 40 50 60 70 80 90 100 120 5 5 6 7 7 8 8 9 9 10 11 12 12 14 15 15 17 20 24 27 29 34 38 41 52 5 6 7 9 9 10 10 11 11 12 13 14 15 16 17 19 21 25 29 32 35 42 46 50 63 7 8 9 10 11 11 12 14 14 15 16 17 18 19 21 23 25 30 34 39 43 51 56 61 77 9 10 11 12 13 14 15 16 17 17 18 20 23 24 25 28 31 38 44 50 56 66 72 78 99 10 12 14 16 17 18 19 20 21 21 23 26 29 30 31 35 39 46 54 62 70 81 89 96 122 13 14 16 18 20 21 23 24 25 25 26 30 34 36 37 42 47 56 65 74 82 97 106 114 145 16 18 20 23 24 26 28 30 32 33 36 39 42 44 46 52 51 70 82 95 106 126 134 149 189 19 22 25 28 30 33 35 37 39 41 45 49 52 55 58 66 73 87 102 119 133 156 171 186 236 23 26 30 33 36 39 42 44 47 49 53 58 62 66 69 78 87 104 121 140 157 187 204 220 280 25 28 32 37 40 43 46 49 52 54 59 64 68 72 76 86 96 114 133 155 173 205 224 242 308 28 32 37 42 46 49 52 57 60 62 67 73 78 82 86 97 108 130 151 177 198 234 265 277 352 31 35 40 46 49 53 56 61 64 67 73 79 85 90 94 106 118 142 165 199 222 263 287 311 395 35 39 45 51 55 59 63 68 72 75 81 93 95 100 105 119 132 158 184 222 248 293 320 347 440 41 46 54 61 66 71 76 82 88 90 97 106 114 120 125 141 157 189 220 265 296 350 284 416 527 1.54 1.50 1.48 1.45 1.43 1.42 1.41 1.40 1.39 1.38 1.38 1.37 1.36 1.36 1.35 1.34 1.33 1.31 1.29 1.28 1.27 1.26 1.26 1.25 1.22

10.3.10

The Steam and Condensate Loop

Block 10 Steam Distribution

Steam Mains and Drainage Module 10.3

Suitability A mains drain trap should consider the following constraints:

o

Discharge temperature - The steam trap should discharge at, or very close to saturation temperature, unless cooling legs are used between the drain point and the trap. This means that the choice is a mechanical type trap (such as a float, inverted bucket type, or thermodynamic traps). Frost damage - Where the steam main is located outside a building and there is a possibility of sub-zero ambient temperature, the thermodynamic steam trap is ideal, as it not damaged by frost. Even if the installation causes water to be left in the trap at shutdown and freezing occurs, the thermodynamic trap may be thawed out without suffering damage when brought back into use. Waterhammer - In the past, on poorly laid out installations where waterhammer was a common occurrence, float traps were not always ideal due to their susceptibility to float damage. Contemporary design and manufacturing techniques now produce extremely robust units for mains drainage purposes. Float traps are certainly the first choice for proprietary separators as high capacities are readily achieved, and they are able to respond quickly to rapid load increases.

Steam traps used to drain condensate from steam mains, are shown in Figure 10.3.14. The thermostatic trap is included because it is ideal where there is no choice but to discharge condensate into a flooded return pipe. The subject of steam trapping is dealt with in detail in the Block 11, Steam Trapping.

Ball float type

Thermodynamic type Thermostatic type Fig. 10.3.14 Steam traps suitable for steam mains drainage

Inverted bucket type

Steam leaks
Steam leaking from pipework is often ignored. Leaks can be costly in both the economic and environmental sense and therefore need prompt attention to ensure the steam system is working at its optimum efficiency with a minimum impact on the environment. Figure 10.3.15 illustrates the steam loss for various sizes of hole at various pressures. This loss can be readily translated into a fuel saving based on the annual hours of operation.
500 Steam leak rate kg /h 400 300 200 100 0 1 3 4 5 Steam pressure bar g Fig. 10.3.15 Steam leakage rate through holes 2 10 mm Orifice size 12.5 mm

7.5 mm 5 mm 3 mm 10

The Steam and Condensate Loop

10.3.11

Block 10 Steam Distribution

Steam Mains and Drainage Module 10.3

Summary
Proper pipe alignment and drainage means observing a few simple rules:
o

Steam lines should be arranged to fall in the direction of flow, at not less than 100 mm per 10 metres of pipe (1:100). Steam lines should be drained at regular intervals of 30 - 50 m and at any low points in the system. Where drainage has to be provided in straight lengths of pipe, then a large bore pocket should be used to collect condensate. If strainers are to be fitted, then they should be fitted on their sides. Branch connections should always be taken from the top of the main from where the driest steam is taken. Separators should be considered before any piece of steam using equipment ensuring that dry steam is used. Traps selected should be robust enough to avoid waterhammer damage and frost damage.

o o

10.3.12

The Steam and Condensate Loop

Block 10 Steam Distribution

Steam Mains and Drainage Module 10.3

Questions
1. Which of the following is true of wet steam?

a| It can cause waterhammer if allowed to build up b| It can corrode pipes if allowed to continue c| It causes erosion of bends d| All of the above 2. What is the effect of installing a steam main horizontally level?

a| None, provided the pipe is drained at 30 - 50 m intervals b| Complete drainage will be less effective, and waterhammer could result c| Larger diameter drain points should be fitted d| Condensate will not reach the drain points 3. Steam pipeline strainers should be fitted with their baskets on the side to:

a| Prevent condensate filling the body and being carried over to the equipment being protected b| Provide a greater screening area c| Extend the periods between cleaning the strainer d| Provide more effective removal of the debris 4.

Using the velocity method, what size pipe is required to carry 500 kg /h of steam at 6 bar g over a 40 m run with a rising slope? (The specific volume of steam at 6 bar g is 0.272 m /kg

a| 40 mm b| 80 mm c| 50 mm d| 65 mm

The Steam and Condensate Loop

10.3.13

Block 10 Steam Distribution

Steam Mains and Drainage Module 10.3

5.

A correctly sized pilot operated reducing valve has been installed in a pressure reducing station supplying an autoclave, as shown in Figure 10.3.16. What is wrong with the installation?
DN20 pressure reducing valve Safety valve

DN25 stop valve Steam at 7 bar g DN25 separator

DN25 strainer

DN32 stop valve

280 kg /h of steam at 5 bar g

Steam trap set

Condensate

Fig. 10.3.16

a| The pipe after the PRV is at a lower pressure, and steam has a higher volume, so the pipe should be larger than 32 mm b| The upstream strainer and isolation valve should be the same size as the reducing valve c| The separator should be one size larger than the pipework to avoid excessive pressure drop d| There is no downstream pressure gauge before the DN32 stop valve 6.

As a minimum, horizontal runs of 150 mm steam main should be drained at intervals of:

a| Every 15 metres via 100 mm bore drain pockets, 100 mm deep b| Every 30 - 50 metres via 150 mm bore drain pockets, 100 mm deep c| Every 15 metres via 100 mm bore drain pockets, 150 mm deep d| Every 30 - 50 metres via 100 mm bore drain pockets, 150 mm deep

10.3.14

1: d, 2: b, 3: a, 4: d, 5: d, 6: d
The Steam and Condensate Loop

Answers