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TATA CONSULTING ENGINEERS

SECTION: TITLE

TCE.M6-ME-590-416

DESIGN GUIDE FOR AUXILIARY STEAM HEADER

SHEET

i

OF iii

DESIGN GUIDE

FOR

AUXILIARY STEAM HEADER

SHEET i OF iii DESIGN GUIDE FOR AUXILIARY STEAM HEADER FLOPPY NO FILE NAME : :

FLOPPY NO

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:

:

M6590416.DOC

REV.NO

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R1

INITIALS

SIGN

INITIALS

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INITIALS

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INITIALS

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PPD.BY

RS

Sd/-

VS

CKD.BY

BVR

Sd/-

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Sd/-

MLN/RL

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DATE

86-06-24

2000-03-31

FORM NO. 020R2

   

TATA CONSULTING ENGINEERS

SECTION:CONTENTS

TCE.M6-ME-590-416

DESIGN GUIDE FOR AUXILIARY STEAM HEADER

SHEET

ii

OF iii

 

CONTENTS

SL.NO.

TITLE

SH.NO.

 

1.0

INTRODUCTION

1

2.0

HEADER SIZE

1

3.0

HEADER FABRICATION

1

4.0

HEADER DRAINAGE

2

5.0

ISOLATING VALVES

2

6.0

SPACING BETWEEN BRANCHES

2

7.0

SUPPORT OF HEADER

3

8.0

PIPE REACTIONS

3

FIGURES

FIGURE - 1

-

STEAM HEADER

4

FIGURE - 2A

-

DRAIN POT WITH TRAP STATION

5

FIGURE - 2B

-

DRAIN POT WITH M.O VALVE

5

FIGURE - 3

-

ANCHOR ON CONCRETE PEDESTAL

6

FIGURE - 4

-

SLIDING SUPPORTS ON CONCRETE PEDESTALS

7

FIGURE - 5

-

ANCHOR ON STRUCTURAL STEEL

8

FIGURE - 6

-

SLIDING SUPPORT ON STRUCTURAL STEEL

8

 

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TATA CONSULTING ENGINEERS

SECTION:REV.STATUS

TCE.M6-ME-590-416

DESIGN GUIDE FOR AUXILIARY STEAM HEADER

SHEET

iii

OF iii

REVISION STATUS

DATE

86-06-24

2000-03-31

REV.NO

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R1

DESCRIPTION

-

Generally revised

ISSUE

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FORM NO. 120 R1

TATA CONSULTING ENGINEERS

SECTION:WRITE-UP

TCE.M6-ME-590-416

DESIGN GUIDE FOR AUXILIARY STEAM HEADER

SHEET

1

OF 8

1.0

INTRODUCTION

The distribution of auxiliary steam to various consumers should preferably be through a header (distributor) which is a short length of adequately-sized pipe and to which the supply sources and consumer points are connected. Branch connections are provided on top of the header for all incoming and outgoing pipelines. The header itself is located just above the floor or platform level. The arrangement of the auxiliary steam header in a typical power plant is shown in Fig.1. The principal design features of the auxiliary steam header are discussed in the following paragraphs. Though power plant applications are discussed, the principles involved are applicable to other types of plants as well.

2.0

HEADER SIZE

The header should be sized for the maximum flow to be handled by it. In a power plant, the design flow of the header is either the capacity of the auxiliary PRDS connected to it or the maximum flow that can be imported into the unit from another unit or package boiler through the interconnecting line, whichever is greater. Generally, headers are designed for lower velocities than pipelines in order to permit future expansion and / or effect trapping of moisture / condensate entrained in steam.

3.0

HEADER FABRICATION

3.1 The header with its nozzles can be fabricated in one of the following ways :

a) By welding a series of tees with spool pieces, as required, in between

b) By welding stubs of the required sizes to the header in which the openings have already been made. The joints are secured through intersection welds.

c) By using “Weldolets” or “Sockolets” depending on the branch size.

3.2 The first method is to have auxiliary steam header using standard wrought steel tees with spool pieces.

3.3 The second method employs intersection of joints. The openings in the header weaken it and additional wall thickness has to be provided on the header by way of reinforcement. The need for additional wall thickness for the branch lines should also be examined. In short, reinforcement calculations have to be carried out for the header. Refer BS : 806 / ASME B 31.1 / IBR for performing reinforcement calculations.

3.4 In the third method, weldolet type fittings are used alongwith openings made in the header. These provide full strength joints without the need for additional reinforcement. It is suggested that preference is given to the use of weldolets as the amount of welding on the header is substantially reduced.

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TATA CONSULTING ENGINEERS

SECTION:WRITE-UP

TCE.M6-ME-590-416

DESIGN GUIDE FOR AUXILIARY STEAM HEADER

SHEET

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OF 8

4.0 HEADER DRAINAGE

4.1 The header being at floor level is a receptacle for condensate formed in the

branch lines. A drain pot should be provided on the header near one end with

a size as per guidelines given in Note-1 of Fig-1. The header should be

sloped towards the drain pot. All branch lines should be sloped towards the header. The condensate collected in the drain pot is drained either through a trap or though a motor operated valve, actuated by level switch. Refer Figs. 2A and 2B. The scheme depends on system requirements, operating pressure and temperature and the quantity of drain to be handled. Traps are adequate to handle small drain quantities at relatively low pressure and temperature.

4.2 Motor operated valve actuated with level switch is recommended when the operating temperature is greater than 400 o C or at places where spray water is introduced into steam piping (e.g. downstream of desuperheater, downstream

of HP Bypass valves).

5.0

ISOLATING VALVES

Isolating valves on branch lines should be located close to the header. The centre line elevations of the valves should be uniform and should be 1300–1500 mm above the floor. Valves may be staggered to reduce the centre distances between branch lines. This arrangement presents a neat appearance renders the operation of valves convenient and ensures quick and ready identification of the service of the valves. This arrangement implies that the length of the stubs on the header, upto the valves, may not be uniform for all branch lines due to differences in end-to-end lengths of valves. This is however of little consequence.

6.0

SPACING BETWEEN BRANCHES

The spacing between the branch pipes on the header is governed by the following two requirements.

a) The clear spacing between two branches should be equal to or greater than the sum of the outside diameter of the two branch pipes in order to avoid the influence of one branch on the other and thus minimise reinforcement requirements. This will not be applicable if weldolets are used.

b) The hand wheels of the isolating valves on adjacent branch lines should have adequate clearance in between for ease of operation. The minimum clearance between the outer edges of the valves should not be less than 150MM.

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TCE.M6-ME-590-416

TATA CONSULTING ENGINEERS

SECTION:WRITE-UP

DESIGN GUIDE FOR AUXILIARY STEAM HEADER

SHEET

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OF 8

7.0 SUPPORT OF HEADER

The header should be supported from the floor through bottom pipe supports. As the steam piping is hot and calls for thermal analysis, the header at one of the support points should be anchored so as to split the piping connected in to individual systems for purpose of stress analysis and to minimise the effect of one branch on the other. Individual systems stress analysis shall be carried out with header anchor as the anchor. Figures 3 to 6 indicate typical arrangement for support of anchor and restraints.

8.0 PIPE REACTIONS

As each pipeline connected to the header is being stress analysed individually, the combined effect of all the pipe reactions at the various take- off points should be studied and the header stress computed. Similarly, the anchor and restraints on the header should be designed for the combined effect of pipe reactions. Here it should be borne in mind that it is not necessary for all the pipe lines to be hot or cold simultaneously. While computing the combined reactions, the worst possible combination of the individual reactions should be considered. The effect due to the reaction forces of safety relief valves that are mounted on the steam header also need to be considered while designing the anchors & restraints. Safety valves should preferably be located near one of the supports of the header.

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TATA CONSULTING ENGINEERS

SECTION:FIGURES

TCE.M6-ME-590-416

DESIGN GUIDE FOR AUXILIARY STEAM HEADER

SHEET

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OF 8

TI SAFETY PI RELIEF VALVE STEAM HEADER SLOPE FLOOR LEVEL PIPE SUPPORT WELD CAP(TYP) SEE
TI
SAFETY
PI
RELIEF VALVE
STEAM HEADER
SLOPE
FLOOR LEVEL
PIPE SUPPORT
WELD CAP(TYP)
SEE FIG-4
FOR DETAILS
PIPE ANCHOR
SEE FIG-3 & 5
FOR DETAILS
DRAIN POT
SEE FIG-2A & 2B
FOR DETAILS
ELEVATION
TI
PI
PLAN
150 MIN.
(TYP)
1300 TO 1500 mm
STEAM FROM
AUX. PRDS.
STEAM TO BOILER FUEL
OIL SYSTEM & SCAPH
SPARE CONNECTION
STEAM TO DEAERATOR
STEAM TO EJECTORS
INTER CONNECTING LINE
BETWEEN UNIT HEADERS
STEAM TO TURBINE
GLAND SEALS
SPARE

FIGURE.-1

STEAM HEADER

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TATA CONSULTING ENGINEERS SECTION:FIGURES TCE.M6-ME-590-416 SHEET 5 OF 8 DESIGN GUIDE FOR AUXILIARY STEAM HEADER
TATA CONSULTING ENGINEERS
SECTION:FIGURES
TCE.M6-ME-590-416
SHEET
5
OF 8
DESIGN GUIDE FOR AUXILIARY STEAM HEADER
SLOPE
C OF HEADER
L
DRAIN POT
TRAP STATION
(REF. NOTE-1)
NB 25
T
TO FLASH TANK OR WASTE
AS SHOWN IN FLOW DIAGRAM
DRAIN PLUG
(THREADED / WELDED
HALF COUPLING WITH PLUG)
FIGURE-2A
DRAIN POT WITH TRAP STATION
SLOPE
C OF HEADER
L
LEGEND
HHLVL
HHLVL
HIGH HIGH LEVEL
PROBE TYPE
HLVL
HIGH LEVEL
LEVEL SWITCH
HLVL
M
DRAIN POT
(REF. NOTE-1)
NB50
TO FLASH
TANK
(REF. NOTE-2)
DRAIN PLUG
(THREADED / WELDED
HALF COUPLING WITH PLUG)
FIGURE-2B
DRAIN POT WITH M.O VALVE
NOTES:
1. DRAIN POT SIZE SHALL BE AS FOLLOWS
HEADER <
150
mm
SAME AS HEADER SIZE
HEADER >
200
mm
HALF THE HEADER SIZE
OR 150 mm WHICH EVER IS GREATER.
2. WITH HIGH HIGH LEVEL THE MOTOR OPERATED VALVE WILL OPEN AND
CLOSE AT HIGH LEVEL
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FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION:FIGURES TCE.M6-ME-590-416 SHEET 6 OF 8 DESIGN GUIDE FOR AUXILIARY STEAM HEADER
TATA CONSULTING ENGINEERS
SECTION:FIGURES
TCE.M6-ME-590-416
SHEET
6
OF 8
DESIGN GUIDE FOR AUXILIARY STEAM HEADER
DO NOT DRILL HOLE
STUB
A
D
A
PLATE 10THK.
2 mm
VENT HOLE
PF
LEGEND
CC
PF
:
PIPE FABRICATOR
CC
: CIVIL CONTRACTOR
POCKET SIZE
50 S.Q. x 300 LONG
100
FOR b < 300
125
FOR b = 301 TO 400
STUB SIZE
DIM. IN mm.
ELEVATION
NB
OD(D)
a
b
b
50
60.3
75
120
a
65
73.0
90
140
80
88.9
110
160
100
114.3
140
190
150
168.3
190
240
200
219.1
240
300
250
273
300
350
SECTION A-A
300
323.9
340
400
FIGURE-3
ANCHOR ON CONCRETE PEDESTAL
ERECTION NOTES:
1.
THE GROUTING SHOULD BE DONE AFTER SETTING THE PIPE LINE FOR SLOPE
2.
HEIGHT OF FOUNDATION SHOULD BE CALCULATED CONSIDERING THE ACTUAL PIPE
ELEVATION AFTER SLOPE AT THE POINT OF SUPPORT
3.
PIPE STUB IS NORMALLY ONE OR TWO SIZES SMALLER THAN HEADER SIZE
4.
PIPE STUB WALL THICKNESS SHOULD BE CHECKED FOR WORST POSSIBLE COMBINED
PIPE REACTIONS AT ANCHOR. THE REACTIONS FORCES MUST BE INDICATED ON THE
PIPING DRAWING TO ENABLE THE PIPING FABRICATOR TO DESIGN WELD JOINTS.
ISSUE
R1
INSULATION
THICKNESS +
25mm(TYP)
OR 100 mm
(MIN)
b
25 GROUT(MIN.)

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION:FIGURES TCE.M6-ME-590-416 SHEET 7 OF 8 DESIGN GUIDE FOR AUXILIARY STEAM HEADER
TATA CONSULTING ENGINEERS
SECTION:FIGURES
TCE.M6-ME-590-416
SHEET
7
OF 8
DESIGN GUIDE FOR AUXILIARY STEAM HEADER
DO NOT DRILL HOLE
A
D
A
2 mm
STUB
PLATE 10THK.
VENT HOLE
PF
CC
2 mm
(TYP)
POCKET SIZE
50 S.Q. x 300 LONG
100
FOR b <
300
125
FOR b = 301 TO 400
ELEVATION
PIPE MVT.
b
=
a
+ PIPE MOVEMENT IN
THE DIRECTION + 100mm.
a
c
=
a
+ 200mm.
d
=
b + 100mm
a
=
SAME AS IN FIG. 3
c & d COULD BE MADE EQUAL
IF THERE IS NOT MUCH
DIFFERENCE.
LEGEND
PF
:
PIPE FABRICATOR
100
FOR b
< 300
125
FOR b
>
301 TO 400
CC
:
CIVIL CONTRACTOR
c
SECTION A-A
FIGURE-4
SLIDING SUPPORTS ON CONCRETE PEDASTALS
ERECTION NOTES:
SAME AS NOTES 1 & 3 OF FIGURE - 3
ISSUE
R1
INSULATION
THICKNESS +
25mm(TYP)
OR
100 mm
(MIN)
d
b
25 GROUT(MIN.)

FORM NO. 120 R1