Five common steam line sizi...

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Five common steam line sizing errors

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When operating a boiler for process or building heat,

engineers deal with a dynamic system. Phase
changes, mass and energy balances, mixed-phase flows, non-Newtonian compressible gases, changes in
pressure and velocity, and production-based or seasonal load swings are characteristics of this complex system.
Across the breadth of steam systems field engineers encounter, most steam systems are far from perfect. Some
problems result from inadequate design and some developed in the course of expansions or modifications. Many
of the problems involve incorrect steam and condensate line pipe sizing.
The effects of these errors range from noise and erosion to equipment damage, erratic process control, safety
hazards, and higher fuel costs. Understanding the causes and effects of these errors can go a long way to
minimizing damage and improving the reliability of the system.
Sizing errors and effects
Incorrectly sized distribution piping
In the past many process plants have used higher steam velocities, approximately 60.96 meters/sec, reasoning
that increased pipe noise is not a problem within the process plant.
Noise is not the sole issue. Only where appreciable superheat (dry gas) is employed should velocities exceed
36.57 meters/sec.
Undersized distribution piping introduces problems such as:
Higher pressure dropInsufficient steam flow to point of useHigh risk of water hammer, noise, and erosion
problems.
Oversized distribution piping introduces problems such as:
Unnecessarily expensive large-diameter piping, support pipe, fittings, valves, and installation laborHigh heat
losses from excessive condensate formation due to the greater surface area of the steam pipePoor steam quality
caused by the formation of additional condensate.
Problems can occur when it is decided that boiler pressure can be changed without consideration of the existing
pipe size. The most cost-effective method is to run the boiler at its design pressure and reduce the pressure at
the point of usage.

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Assume it is planned to set a 1,564.89 kilograms (100 hp) rated boiler at the 50-psig requirements of the process
systems. The resulting steam would occupy a volume of 0.18 m3/lb. For acceptable velocities this pressure
setting would require a 10.16-cm steam line. However, if the same boiler is set at 200 psig, steam tables show
the volume reduces to 0.06 m3/lb, requiring only a 5.08-cm steam pipe.
Look at the economic impact. A 60.96-meters, 5.08-meters, Sch. 40 main steam line would cost three times
more than a 60.96-meters,5.08-meters main line.
Undersized piping downstream of pressure reducing valves
Assume the boiler is set at 200 psig, 5.08-meters steam lines are used, and a 5.08-meters pressure-reducing
valve (PRV) is specified to provide the 50-psig steam required by the process. However, the same 5.08-cm
piping for the PRV inlet is used for the outlet. This is the third common problem encountered.
Velocity through the pressure reduction station must be considered when sizing fittings and components.
Designers sizing these lines often fail to properly consider the significant increase in specific volume of steam
with reduced pressure. If the designer had checked the specific volume at the two pressures, he would have
seen that the steam at reduced pressure occupies more volume, and the outlet piping has to be a minimum of
10.16-meters to maintain reasonable velocity.
This error would result in much higher steam velocities downstream of the PRV and a high level of noise. The
high velocity could cause premature erosion of the outlet piping and downstream components.
Undersized condensate piping downstream of traps
Steam performs its work (gives up its latent heat) and condenses back to water. This condensate is usually
discharged from the steam lines at system operating pressure by a properly sized and selected steam trap.
Pipe sizing for condensate recovery takes on a new dimension: two-phase flow brought about by the larger
effective volume and reduced pressure of the condensate system. When hot condensate under pressure is
released to a lower pressure, its temperature must drop very quickly to the boiling point for the lower pressure.
This sensible heat released from the liquid condensate causes some re-evaporation into flash steam, and the
two phases are present in the condensate system.
If the condensate pipes are undersized by neglecting the presence of flash steam, the result is increased back
pressure and velocity, this time with a liquid phase that could lead to water hammer. Severe water hammer can
cause damage to steam system pipes, equipment, and personnel. Increased back-pressure can create problems
with process equipment.
Improperly sized pumped condensate return lines
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Condensate is an energy resource that should be returned to the boiler feed water system. Pumped condensate
return lines in a properly engineered system only carry water. Flow rates of no more than 1.82 to 2.43 meters/sec
should be used for proper pipe sizing.
Check for sizing errors
Make use of several basic principles and methods to assess a steam system for potential problems.
First, keep in mind which part of the steam system is being assessed:
Generation and distribution (gas phase)Pressurized condensate return (mixed phases)Pumped condensate
recovery (liquid phase)
Since steam is a compressible gas; pressure and volume are inversely proportional. As steam pressure
increases, the volume of space it occupies (specific volume) decreases. Steam tables and pressure/specific
volume graphs are useful in quantifying the relationship between steam pressure and volume to size piping
correctly.
Piping should be sized with consideration for fluid velocity and pressure drop. For velocity, the relationships
among the saturated steam velocity, specific volume, and pipe diameter is:
V = (2.4QVs)/A
where:
V = Velocity, ft/min
Q = Steam flow, lb/hr
Vs = Specific volume at flow pressure, ft3
/lb
A = Internal cross-sectional pipe area, inch2
To size by pressure drop, make use of a variation of the D'Arcy Equation that calculates pressure loss due to
friction for straight pipe of constant diameter for fluids of reasonably constant density.
dP = (pfLv
2)/(144D2g)
where:
dP = Differential pressure, psi

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p = Density of fluid, lb/ft3

f = Friction factor (dimensionless)
L = Length of pipe, ft
v = Flow velocity, ft/sec
D = Internal pipe diameter, ft
g = Gravitational constant (9.81 meters/sec2
)
Since the values for 'f' are complex, they are generally obtained from tables.
Constant velocity after PRVs
Downstream piping cross-sectional area must be larger by the same ratio as the change in volume. Consult
steam tables for the specific volume of saturated steam for the two pressures, then calculate the ratio of the
downstream pressure to the upstream pressure (always greater than 1).
Use the velocity equation to solve for cross sectional area of the high-pressure side for the design velocity and
flow rate. Then multiply the cross sectional area by the ratio to figure what the cross sectional area of the lowpressure side should be. Use pipe size tables to find a pipe diameter for the pipe schedule being used.
Piping downstream of traps
Taking flash steam into consideration, condensate piping has to be sized based on two-phase flow (the presence
of steam and condensate). A portion of the pipe will be occupied by flash steam and the balance with
condensate.
Line velocity of no more than 15.24 to 18.288 meters/sec is recommended for condensate return lines and vent
pipes. Sizing programs and nomographs are available that combine sizing calculations for the size of a flash
vessel, condensate line, and flash steam vent line in one chart. This can help to correctly size all two-phase flow
components.
Condensate return lines
Condensate line sizing can be checked with the aid of readily available charts or programs correlating flow rate,
flow velocity, pressure drop, and pipe diameter. Apply friction loss per length of pipe run, and friction equivalents
(in straight pipe length) of the various tees, elbows, and other fittings in the line to these results.
Check the capacity of installed condensate pumps in relation to return line flow rates. Electric pumps are usually
sized with a pumping capability of 2 to 3 times the rate at which condensate reaches the receiver.
Beyond pipe sizing
Correct steam pipe sizing is critical not only for energy efficiency, but also for safety. Provide good quality steam
at the required demand and pressure of the user. By using the proper tools, a steam system can be sized to
optimum conditions, with minimum heat loss and maintenance attention.
These sizing considerations underscore the importance of auditing a steam system periodically, especially
whenever process equipment is altered, or boiler ratings or operating conditions are changed. This inexpensive
process and the resulting optimization measures can preserve plant efficiency, maintainability, and safety.
More Info:
Questions about steam line sizing should be directed to 800-833-3246. For more information on allowing for flash
steam in piping refer to Design of Fluid Systems-Hook-Ups, Spirax Sarco, Inc., 12th edition.
5 common pipe sizing problems:Vincent Ferguson, Alan StanderwickIncorrectly sized distribution piping, from not
optimizing steam velocity.Oversized distribution piping, from altered boiler operating conditionsUndersized piping
downstream of pressure reducing valves, from failing to consider changes in steam velocity and specific
volume.Undersized condensate piping downstream of traps, ignoring the presence of two-phase flow.Improperly
sized condensate return lines, from failure to differentiate between pressurized and pumped condensate.
Pipe friction data Pipe size
, inch11/122-34568-1012-1618-24Friction factor
, f0.0270.0250.0230.0220.0210.0190.0180.0170.0160.0150.0140.0130.012
16.01.2006
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