Steam Distribution System

Steam Distribution
Academic Manual AC/02/01
Open University Project
Steam Distribution
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Typical Steam Circuit

Steam Space Heating System Condensate Steam Process Vessel Vat
Pan
Pan
Steam
Make-up Water Feed Pump Feed Tank Condensate
Boiler
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Steam flow meter.
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Vortex flow meter
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Specific Volume Vs Pressure of Saturated Steam

1.8 1.6 1.4 (m3/kg) Specific Volume 1.2 1 0.8 0.6 0.4 0.2 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Pressure (bar g)
Open University Project Steam Distribution AC/02/01 5
Pipes and Pipe SizingPipe material

Pipe Metal:carbon steel to ASME B 16.9 A106 Standards and wall thickness Pipe standardTopic summery) > API/BS-1600 : Scheduled number pipe like as ;40,80,100, etc > DIN 2448 : 40 schedule pipes is lesser thickness than 80 schedule pipe. So if need more thickness able pipe , go more schedule number. In case of thickness 40<60<80<100<120<140 etc
Steam Distribution
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Pressure Reducing Station
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The proportional band being too narrow. The integral time being too short. The derivative time being too long. A combination of these. Long time constants or dead times in the control system or the process itself.
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Single loop controller with chart recorder
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Steam Tables
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Distribute at High Pressure

This will have the following advantages:
> Smaller bore steam mains needed and therefore less heat (energy) loss due to the smaller surface area. > Lower capital cost of steam mains, both materials such as pipes, flanges and support work and labour. > Lower capital cost of insulation (lagging). > Dryer steam at the point of usage because of the drying effect of pressure reduction taking place. > The boiler can be operated at the higher pressure corresponding to its optimum operating condition, thereby operating more efficiently. > The thermal storage capacity of the boiler is increased, helping it to cope more efficiently with fluctuating loads, and a reduced risk of priming and carryover
Pipe Sizing
Greater Cost Greater Heat Loss Greater Volume of Condensate Formed
Lower Pressure to Steam Users Not Enough Volume of Steam Water Hammer and Erosion
How is Pipe Sized?
On the basis of:

> Fluid Velocity > Pressure Drop
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Pipe Thickness and Standard Sizes
pD t= 2S + p 2
Where: t = internal pressure design thickness (mm) p = internal design pressure in bar, (105 N/mm2) D = outside diameter of pipe in millimetres S= design stress in N/mm2, (MN/m2)
Steam Pipe Sizing Chart (kg/h)

Pressure Velocity bar g m/s 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 22 . 2 2 2. 22 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 22 2 2 2 2 2 22 2 2 2 2 2 .2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 22 2 2 2 2 2 22 2 2 2 2 2 22 2 2 2 22 2 22 2 2 2 22 2 22 2 2 2 2. 2 22 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 22 2 2 2 22 2 22 2 2 2 22 2 22 2 2 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 Pipe Size Nominal / Actual Inside Diameter 2 2 2 2 2 2 2 2 2 2 2. 2 22 2. 22 2. 22 2 2 .2 2. 2 22 2 2 2 2 2 2 22 2 22 2 2 2 2 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 2 2 2 2 22 2 22 2 22 2 2 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 2 2 2 2 22 2 22 2 22 2 2 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 2 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 22 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 22 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 22 22 2 22 2 22 2 22 22 22 22 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 22 22 2 22 2 22 2 22 22 22 22 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 22 22 22 22 2 22 2 22 22 22 22 22 22 22 2 22 2 22 2 22 2 22 22 22 2 22 2 22 2 22 22 22 22 22 2 22 2 22 22 22 22 22 22 22 2 2 22 2. 2 22 2 22 2 22 2 22 2 22 2 22 22 22 2 22 2 22 22 22 2 22 22 22 22 22 2 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 2 2 22 2. 22 2 22 2 22 22 22 2 22 22 22 22 22 2 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 2 2 22 2. 2 22 2 22 22 22 22 22 2 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 222 22
22 .
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Band Marking
Red Band - Heavy Grade Up to 4 m in length
Blue Band - Medium Grade Between 4 m - 7 m in length
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Pipeline Capacity and Pressure Drop

P1
Fluid Flow
P2
P2- P2 = F (Pressure Drop Factor) L

P1:- pressure factor at pressure P1 P2:- pressure factor at pressure P2
Pressure Factors for Pipe Sizing

Pressure bar g 2 2 .2 22 . 22 . 22 . 22 . 22 . 22 . 22 . 22 . 2 22 . 22 . 22 . 22 . 22 . 22 . 22 . 22 . 22 . 2
Open University Project Steam Distribution
Volume m 2 /kg 22 2 . 2 2 .2 2 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2
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Pressure Factor 2. 2 22 2. 2 22 2 2 .2 2 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 22
Pressure Factors for Pipe Sizing

Pressure bar g 2 22 . 22 . 22 . 22 . 22 . 22 . 22 . 22 . 22 . 2 22 . 22 . 22 . 22 . 22 . 22 . 22 . 22 . 22 . 2
Volume m 2 /kg 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2 22 2 . 2
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Pressure Factor 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 2 22 2. 22
Pipe Sizing Example
195 m + 10% = 214 m equivalent pipe length
Boiler 7 bar g 289 kg/h
Heater Battery 6.6 bar g 270 kg/h
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Velocity Factor (y)
True Velocity x 2 y= Actual Volume
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Pipeline Capacity and Pressure Drop Factors

Pipe Sizes (mm) F 22 2x . 2 2 2 22 . 2 2 2 2 2 2 2 2 2 2 2 2 2 2 22 2 22 2 22 2 222 22 2 22 2 22 2 22 2
2 . 2 2 . 2 2 22 2 22 2 2 2 22 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 22 22 2. 2. 2 2. 22 22 22 22 22 22 22 22 22 22 2 22 2 2 22 2.
y 2 . 2 2 . 2 2 . 2 2 . 2 2 22 2 22 2 . 2 2 . 2 2 2 2 22 2 22 2 22 2 22 22 22 22 22 2. 2. 22 22 22 2. 2. 2. 2.
22 2x 2 . 2 2 . 2 2 . 2 2 22 2 22 2 22 2 22 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 . 2 22 22 22 2. 2. 2. 2. 22 22 22 22 22 22 22 22 22 y 22 2x . 2 2 2 2 2 2. 22 2 . 2 2 . 2 2 . 2 2 . 2 2 . 22 22 22 22 22 2. 22 2 22 2 22 2 2 2 22 2 22 2 22 2 22 2 22 2. 2. 2 2. 2. 2. 2. 2.
2 . 2 2 . 2 2 22 2 22 2 22 2 22 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 22 22 2. 2. 2. 2. 22 22 22 22 22 22 22 22 22
y 2. 2 2. 2 2. 22 22 22 2 . 2 2 . 2 2 . 2 2 . 2 2 . 2 2 22 2 2 2 22 2 22 2 22 2 22 2 22 2 22 22 22 22 22 22 2. 2 2. 2. 2. 2. 2. 2.
22 x 2 . . 2 22 y 2. 22
2. 22 2 2
22 2 2. 22
22 2 2. 22
22 2 2. 22
22 2 22 2
22 22 22 222 222 222 222 22 22 22 22 22 22 22 22 2 22 2 22 2 22 2 22 2 22 2 22 2
x = kg/h capacity y = m/s velocity with a volume of 1m3/kg

Pipeline Capacity and Pressure Drop Factors

Pipe Sizes (mm) F 22 2x . 2 2 2 22 . 2 2 2 2 2 2 2 2 2 2 2 2 2 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2
2 . 2 2 . 2 2 22 2 22 2 2 2 22 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 22 22 2. 2. 2 2. 22 22 22 22 22 22 22 22 22 22 2 22 2 2 22 2.
y 2 . 2 2 . 2 2 . 2 2 . 2 2 22 2 22 2 . 2 2 . 2 2 2 2 22 2 22 2 22 2 22 22 22 22 22 2. 2. 22 22 22 2. 2. 2. 2.
22 2x 2 . 2 2 . 2 2 . 2 2 22 2 22 2 22 2 22 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 . 2 22 22 22 2. 2. 2. 2. 22 22 22 22 22 22 22 22 22 y 22 2x . 2 2 2 2 2 2. 22 2 . 2 2 . 2 2 . 2 2 . 2 2 . 22 22 22 22 22 2. 22 2 22 2 22 2 2 2 22 2 22 2 22 2 22 2 22 2. 2. 2 2. 2. 2. 2. 2.
2 . 2 2 . 2 2 22 2 22 2 22 2 22 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 22 22 2. 2. 2. 2. 22 22 22 22 22 22 22 22 22
y 2. 2 2. 2 2. 22 22 22 2 . 2 2 . 2 2 . 2 2 . 2 2 . 2 2 22 2 2 2 22 2 22 2 22 2 22 2 22 2 22 22 22 22 22 22 2. 2 2. 2. 2. 2. 2. 2.
22 x 2 . . 2 22 y 2. 22
2. 22 2 2
22 2 2. 22
22 2 2. 22
22 2 2. 22
22 2 22 2
22 22 22 222 222 222 222 22 22 22 22 22 22 22 22 2 22 2 22 2 22 2 22 2 22 2 22 2
x = kg/h capacity y = m/s velocity with a volume of 1m3/kg

Pipe Sizing Example
Therefore:
P2- P2 2 2 .2 2 - 2 . 2 22 F= = = 22 2 . 2 L 222
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True Velocity
The true velocity of the example system using a 50 mm pipe is:
True Velocity x 2 y= Actual Volume True Velocity 2. 2 22 = 22 . 2 True Velocity = 22 . m/s

Comparison of Results at 21m/s

2 . 2 P2 22 = 22 . 2 22 2
Therefore P2 = 39.26 which from the pressure factors table is equivalent to a pressure of just below 5.7 bar. So had the pipe line been installed as a 40 mm size instead of 50 mm the pressure at the heater battery would have been below the design condition.
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Branch Lines
For short branch lines only the specific velocity needs to be considered. Pressure drop can be ignored. IF IN DOUBT USE BOTH AND COMPARE
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Pipe Alignment and Drainage

Fl o w
Separator
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Waterhammer
Sagging Main
Condensate
Slug of water from condensate
Vibration and noise caused by waterhammer
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Relaying to Higher Level

Fall 1/250
Steam
30 - 50m Drain Points
Relay to high level
Steam Flow Flow
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Ineffective, and Proper Drain Points

Steam Flow Condensate
Correct
Pocket 25/30m Steam Trap Set
Cross Section
Steam Flow
Cross Section
Incorrect
Steam Trap Set
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Steam Line Reducers

Ste am Correct
Condensate
Ste am
Incorrect
Condensate
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Strainers
Control Valve Strainer
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Branch Connections
Ste am
Ste am
Condensate
Incorrect
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Correct
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Drop Leg
Main
Shut Off Valve
Trap Set
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Reverse Gradient On Steam Main
m 15
30-50m Steam Velocity up to 40 m/s 30-50m Increase in Pipe Diameter So That Steam Velocity Is Reduced to 15 m/s
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Mains Drain Traps
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Warm Up Loads/Running Loads (kg per 50 m of Steam Main)

Steam Pressure (bar g) 2 2 2 2 2 2 2 2 2 2 2 22 2 2 2 2 1 1 .1 22 2 . . 22 2 2 .2 22 2 . . 22 1 1 .1 Steam Main Size (mm) 22 22 22 22 22 22 22 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 22 22 22 22 22 2 2 2 2 2 2 2 2 2 2 2 2. 22 2 . 22 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 22 22 22 22 22 2 2 2 2 2 22 2 22 2 2 2 22 2 2 2 22 2 2 2 22 2 22 2 2 2 22 2 2 2 22 2 2 2
2. 22 2 . 22 2 . 22
2. 22 2 . 22 2 . 22 2 2 2 2
22 2 . . 22 2 . 22 2 . 22 2 . 22 2 . 22 22 2 . . 22 2 . 22 2 . 22 2 . 22 2. 22 2 2 2. 22 2 . 22 2 . 22
2. 22 2 . 22 2 . 22 2 . 22 2 . 22 2 . 22 2 . 22 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
Figures in italics represent running loads Ambient temperature 20 C, insulation efficiency 80%
Steam Trap Types

Thermodynamic Float/Thermostatic Inverted Bucket Thermostatic
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Thermodynamic Steam Trap
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Ball Float Trap
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Inverted Bucket Trap
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Thermostatic Steam Trap
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Calculation of Pipe Expansion
Expansion () = L x t x (mm)
Where: L = t = =
Length of pipe between anchors Temperature difference Expansion coefficient
(m) (oC)
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Expansion Coefficients
For Temp. Range Mild Steel 22- 22% C . . Alloy Steel 2 Cr % Mo % Stainless Steel 2 % Cr 2 Ni 2 % -22 2 - 2 2 2 2. 22 2. 22 22 . 2 2 2. 22 2 2 2 - 222 2 2 2. 22 2. 22 2 - 222 2. 22 2. 22 2. 22 2 - 222 2. 22 2. 22 2. 22 2 - 222 2. 22 2. 22 2. 22 2 - 222 2. 22 2. 22 2. 22 2 - 222 2 2
Expansion Coefficient x 10-6 (m/m) Example: Mild steel for temperature range -300 =12.8 x 10-6 m/m
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Expansion Chart for Mild Steel Pipe

Temperature difference oC/metre
Length of pipe (mm)
Expansion of pipe (mm)

bar g
o
22 . 222
22
2 2
2 2
2 2
2 2
22 22 22 22 2 2 2 2 2 2 2
22 22 22 22 22 2 2 2 2 2
Temperature of Saturated Steam

Pipe Expansion
L Spacer Piece
Half calculated expansion over length L
Position After Cold draw Neutral Position Hot Position

Full Loop
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Horse Shoe Loop
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Steel Expansion Loops

Expansion from Neutral Position (mm)
Nominal Pipe Size (mm)
2W
Welding ends radius =1.5 dia.
Maximum pressure 17 bar o Temperature 260 C

W.Metres
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Sliding Joint
Pressure acts on this area
Movement due to pipework expansion
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Expansion Bellows
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Use of Bellows
Misalignment Steam Flow
Axial Movement
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Anchor Points
Lug Strap Lug
Pipe Flange
Recommended Support Spacing for Steel & Copper Pipe

Nominal Pipe Size Steel/Copper Bore 2 2 2 2 22 2 2 2 2 2 2 2 2 2 2 2 2 22 2 22 2 22 2 22 2 22 2 O/D 22 22 2 2 2 2 2 2 2 2 2 2 2 2 2 2 22 2 22 2 22 2 22 2 22 2 Interval of Horizontal Run (m) Mild Steel 2 22 . 22 . 22 . 2 22 . 22 . 22 . 22 . 22 . 22 . 22 . 22 . Copper 2 22 . 22 . 22 . 22 . 2 2 2 22 . 22 . 2 22 . Interval of Vertical Run (m) Mild Steel 2 .2 2 2 2 2 .2 22 . 22 . 22 . 22 . 22 . 22 . 2 22 . Copper 22 . 22 . 2 .2 2 2 22 . 22 . 22 . 2 .2 22 . 22 . 22 . -
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Rollers for Steel Pipework
Chair & Roller
Chair Roller & Saddle
Twin Pipe Support Bracket
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Air Venting
Balanced Pressure Air Vent
Steam Main
Air
Thermodynamic Steam Trap Set
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Heat Emission from Bare Pipes

Temp. Difference Steam to Air 2 2
o
Pipe Size (mm) 2 2 2 2 2 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 2 2 2 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 2 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 2 2 W/m 2 2 2 2 2 2 2 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 . 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 22 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 22 22 22 22 22 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 22 22 22 22 22 22 22 22 22 2 2 2 2 2 2 22 2 22 2
2 2 2 2 2 2 2 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2 22 2
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Thermal Conductivities of Insulating Materials
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Calculation of Heat Transfer
Q = U. A. t
Where Q = U = A = Dt =
Heat transfer rate (W) Overall heat transfer coefficient (W/m2K) Mean surface area (m2) Temperature difference (K)
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Assignment
1. State in simple terms the disadvantages of an oversized steam main. 2. A steam main must be run uphill, i.e. contra flow to the condensate. What maximum steam velocity should be used, and at what frequency should drain points be installed? 3. In pipe sizing, what do you understand by the term Equivalent Length of Pipe? 4. What is the pressure drop in a 50mm bore steam line with equivalent length of 50 metres, carrying 785 kg/h at an initial pressure of 7 bar g? 5. What would be the pressure drop in question 4 if the equivalent length is increased to 300 metres?
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Assignment
6. A 100 mm bore steam line is to be drained, what size of drain pocket should be used for the drain trap installation and what type of steam trap should be used? 7. What is the approximate warm up load, and running load of a 200 mm bore steam pipe 100 metres long carrying dry saturated steam at 10 bar g with an ambient air temperature of 20C? 8. What pipe size is needed to carry 15000 kg/h of saturated steam at a pressure of 15 bar g. Equivalent length is 700 metres. 9. A steam main is situated external to a building. The ambient temperature can fall to below 0C. What type of steam trap would you use to drain the main? 10.Describe briefly what provision you would make to allow expansion of a steam main to take place without damage occurring to the pipework.
Assignment
11.A steam main is carrying saturated steam at 5 bar g. Its length is 100 metres. What expansion from cold start would be expected to take place? 12.Indicate what distance you would specify between pipe supports for the following sizes of pipes: 40 mm bore steel pipe 100 mm bore steel pipe 28 mm O/D copper pipe 108 mm O/D copper pipe 13.What provisions would you make for reducing the heat loss from flanges and valves on both steam and condensate mains?
Sizing drain lines to traps
Fig. The drain line should not be sized on the plant connection. It should not be assumed that the drain line (and trap) should be the same size as the plant outlet connection. When sizing the drain line, the following will need consideration: 1.The condensing rate of the equipment being drained during full-load. 2.The condensing rate of the equipment at start-up.
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Flash Steam use
Fig. 14.6.5 Flash steam recovery on a multi-bank air heater battery
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Control Valve
A basic control system would normally consist of the following components: Control valves. Actuators. Controllers. Sensors.
Linear type: include globe valves and slide valves. Rotary type: include ball valves, butterfly valves, plug valves and their variants. The first choice to be made is between two-port and three-port valves. Two-port valves 'throttle' (restrict) the fluid passing through them. Three-port valves can be used to 'mix' or 'divert' liquid passing through them.
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Two Port Valve
Fig. Flow through a single seat, two-port globe valve
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Two port Valve
Fig. Butterfly valve (shown in its open position)

Three-port valves
Fig:Three-port valve definition

3 Port valve
Piston valve type. Globe plug type. Rotating shoe type.
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3 Port Valve
Fig: Piston Type 3 port Valve
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Three Port valve
Fig: Globe type three-port valves (also called 'lift and lay')
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3 port valve
Fig: Rotating shoe three-port valve
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Control Valve Actuators and Positioners

Pneumatic actuators - operation and options Pneumatic actuators are commonly used to actuate control valves and are available in two main forms; piston actuators (Figure 6.6.1) and diaphragm actuators
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Fig:A pneumatic diaphragm actuator

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Positioner
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Summery of Positioner
A frequently asked question is, 'When should a positioner be fitted? A positioner should be considered in the following circumstances: When accurate valve positioning is required. To speed up the valve response. The positioner uses higher pressure and greater air flow to adjust the valve position. To increase the pressure that a particular actuator and valve can close against. (To act as an amplifier). Where friction in the valve (especially the packing) would cause unacceptable hysteresis. To linearise a non-linear actuator.</< li> Where varying differential pressures within the fluid would cause the plug position to vary.
Summary - Positioners A positioner ensures that there is a linear relationship between the signal input pressure from the control system and the position of the control valve. This means that for a given input signal, the valve will always attempt to maintain the same position regardless of changes in valve differential pressure, stem friction, diaphragm hysteresis and so on. A positioner may be used as a signal amplifier or booster. It accepts a low pressure air control signal and, by using its own higher pressure input, multiplies this to provide a higher pressure output air signal to the actuator diaphragm, if required, to ensure that the valve reaches the desired position. Some positioners incorporate an electropneumatic converter so that an electrical input (typically 4 - 20 mA) can be used to control a pneumatic valve. Some positioners can also act as basic controllers, accepting input from sensors.
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Control sensor
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Fig: Standard range of thermocouples and their range (C)
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PRV
Plant operating at low steam pressure: Can tend to reduce the amount of steam produced by the boiler due to the higher enthalpy of evaporation in lower pressure steam. Will reduce the loss of flash steam produced from open vents on condensate collecting tanks. Most pressure reducing valves currently available can be divided into the following two main groups: Direct acting valves. Pilot-operated valves.
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PRV
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Pilot PRV
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PRV
Fig:Typical characteristics for different types of pressure reducing valve
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Temperature Control
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Safety Valve
The ASME / ANSI PTC25.3 standards applicable to the USA define the following generic terms: Pressure relief valve - A spring-loaded pressure relief valve which is designed to open to relieve excess pressure and to reclose and prevent the further flow of fluid after normal conditions have been restored. It is characterised by a rapid-opening 'pop' action or by opening in a manner generally proportional to the increase in pressure over the opening pressure. It may be used for either compressible or incompressible fluids, depending on design, adjustment, or application. This is a general term, which includes safety valves, relief valves and safety relief valves. Safety valve - A pressure relief valve actuated by inlet static pressure and characterised by rapid opening or pop action. Safety valves are primarily used with compressible gases and in particular for steam and air services. However, they can also be used for process type applications where they may be needed to protect the plant or to prevent spoilage of the product being processed. Relief valve - A pressure relief device actuated by inlet static pressure having a gradual lift generally proportional to the increase in pressure over opening pressure. Relief valves are commonly used in liquid systems, especially for lower capacities and thermal expansion duty. They can also be used on pumped systems as pressure overspill devices. Safety relief valve - A pressure relief valve characterised by rapid opening or pop action, or by opening in proportion to the increase in pressure over the opening pressure, depending on the application, and which may be used either for liquid or compressible fluid. In general, the safety relief valve will perform as a safety valve when used in a compressible gas system, but it will open in proportion to the overpressure when used in liquid systems, as would a relief valve. The European standard EN ISO 4126-1 provides the following definition: Safety valve - A valve which automatically, without the assistance of any energy other than that of the fluid concerned, discharges a quantity of the fluid so as to prevent a predetermined safe pressure being exceeded, and which is designed to reclose and prevent further flow of fluid after normal pressure conditions of service have been restored.
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Safety Valve
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Differ of ASME & DIN
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Nozzle Safety valve
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Safety valve Approval authorities
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Codes and Standards
Table : Standards relating to safety valves

Types of Safety Valve

The ASME standard I and ASME standard VIII for boiler and pressure vessel applications and the ASME / ANSI PTC 25.3 standard for safety valves and relief valves provide the following definition. These standards set performance characteristics as well as defining the different types of safety valves that are used: ASME I valve - A safety relief valve conforming to the requirements of Section I of the ASME pressure vessel code for boiler applications which will open within 3% overpressure and close within 4%. It will usually feature two blowdown rings, and is identified by a National Board 'V' stamp. ASME VIII valve - A safety relief valve conforming to the requirements of Section VIII of the ASME pressure vessel code for pressure vessel applications which will open within 10% overpressure and close within 7%. Identified by a National Board 'UV' stamp. Low lift safety valve - The actual position of the disc determines the discharge area of the valve. Full lift safety valve - The discharge area is not determined by the position of the disc. Full bore safety valve - A safety valve having no protrusions in the bore, and wherein the valve lifts to an extent sufficient for the minimum area at any section, at or below the seat, to become the controlling orifice. Conventional safety relief valve - The spring housing is vented to the discharge side, hence operational characteristics are directly affected by changes in the backpressure to the valve. Balanced safety relief valve - A balanced valve incorporates a means of minimising the effect of backpressure on the operational characteristics of the valve. Pilot operated pressure relief valve - The major relieving device is combined with, and is controlled by, a selfactuated auxiliary pressure relief device. Power-actuated safety relief valve - A pressure relief valve in which the major pressure relieving device is combined with, and controlled by, a device requiring an external source of energy.
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Type of safety Valve

The following types of safety valve are defined in the DIN 3320 standard, which relates to safety valves sold in Germany and other parts of Europe: Standard safety valve - A valve which, following opening, reaches the degree of lift necessary for the mass flowrate to be discharged within a pressure rise of not more than 10%. (The valve is characterised by a pop type action and is sometimes known as high lift). Full lift (Vollhub) safety valve - A safety valve which, after commencement of lift, opens rapidly within a 5% pressure rise up to the full lift as limited by the design. The amount of lift up to the rapid opening (proportional range) shall not be more than 20%. Direct loaded safety valve - A safety valve in which the opening force underneath the valve disc is opposed by a closing force such as a spring or a weight. Proportional safety valve - A safety valve which opens more or less steadily in relation to the increase in pressure. Sudden opening within a 10% lift range will not occur without pressure increase. Following opening within a pressure of not more than 10%, these safety valves achieve the lift necessary for the mass flow to be discharged. Diaphragm safety valve - A direct loaded safety valve wherein linear moving and rotating elements and springs are protected against the effects of the fluid by a diaphragm. Bellows safety valve - A direct loaded safety valve wherein sliding and (partially or fully) rotating elements and springs are protected against the effects of the fluids by a bellows. The bellows may be of such a design that it compensates for influences of backpressure. Controlled safety valve - Consists of a main valve and a control device. It also includes direct acting safety valves with supplementary loading in which, until the set pressure is reached, an additional force increases the closing force.
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Type of safety Valve

EN ISO 4126 lists the following definitions of types of safety valve: Safety valve - A safety valve which automatically, without the assistance of any energy other than that of the fluid concerned, discharges a quantity of the fluid so as to prevent a predetermined safe pressure being exceeded, and which is designed to re-close and prevent further flow of fluid after normal pressure conditions of service have been restored. Note; the valve can be characterised either by pop action (rapid opening) or by opening in proportion (not necessarily linear) to the increase in pressure over the set pressure. Direct loaded safety valve - A safety valve in which the loading due to the fluid pressure underneath the valve disc is opposed only by a direct mechanical loading device such as a weight, lever and weight, or a spring. Assisted safety valve - A safety valve which by means of a powered assistance mechanism, may additionally be lifted at a pressure lower than the set pressure and will, even in the event of a failure of the assistance mechanism, comply with all the requirements for safety valves given in the standard. Supplementary loaded safety valve - A safety valve that has, until the pressure at the inlet to the safety valve reaches the set pressure, an additional force, which increases the sealing force. Note; this additional force (supplementary load), which may be provided by means of an extraneous power source, is reliably released when the pressure at the inlet of the safety valve reaches the set pressure. The amount of supplementary loading is so arranged that if such supplementary loading is not released, the safety valve will attain its certified discharge capacity at a pressure not greater than 1.1 times the maximum allowable pressure of the equipment to be protected. Pilot operated safety valve - A safety valve, the operation of which is initiated and controlled by the fluid discharged from a pilot valve, which is itself, a direct loaded safety valve subject to the requirement of the standard.
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Table : Safety valve performance summary
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Safety Valve
Conventional safety valves Pilot operated safety valve Full lift, high lift and low lift safety valves Balanced safety valves 1. Piston type balanced safety valve 2. Bellows type balanced safety valve
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Conventional safety valves
Schematic diagram of safety valves with bonnets vented to (a) the valve discharge and (b) the atmosphere
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Balanced safety valvesPiston type balanced safety valve
Schematic diagram of a piston type balanced safety valve
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Bellows type balanced safety valve
Schematic diagram of the bellows balanced safety valve
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Pilot operated safety valve
A piston type, pilot operated safety valve

Full lift, high lift and low lift safety valves

The terms full lift, high lift and low lift refer to the amount of travel the disc undergoes as it moves from its closed position to the position required to produce the certified discharge capacity, and how this affects the discharge capacity of the valve. A full lift safety valve is one in which the disc lifts sufficiently, so that the curtain area no longer influences the discharge area. The discharge area, and therefore the capacity of the valve are subsequently determined by the bore area. This occurs when the disc lifts a distance of at least a quarter of the bore diameter. A full lift conventional safety valve is often the best choice for general steam applications. The disc of a high lift safety valve lifts a distance of at least 1/12th of the bore diameter. This means that the curtain area, and ultimately the position of the disc, determines the discharge area. The discharge capacities of high lift valves tend to be significantly lower than those of full lift valves, and for a given discharge capacity, it is usually possible to select a full lift valve that has a nominal size several times smaller than a corresponding high lift valve, which usually incurs cost advantages. Furthermore, high lift valves tend to be used on compressible fluids where their action is more proportional. In low lift valves, the disc only lifts a distance of 1/24th of the bore diameter. The discharge area is determined entirely by the position of the disc, and since the disc only lifts a small amount, the capacities tend to be much lower than those of full or high lift valves.
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Materials of construction
The principal pressure-containing components of safety valves are normally constructed from one of the following materials: Bronze - Commonly used for small screwed valves for general duty on steam, air and hot water applications (up to 15 bar). Cast iron - Used extensively for ASME type valves. Its use is typically limited to 17 bar g. SG iron - Commonly used in European valves and to replace cast iron in higher pressure valves (up to 25 bar g). Cast steel - Commonly used on higher pressure valves (up to 40 bar g). Process type valves are usually made from a cast steel body with an austenitic full nozzle type construction. Austenitic stainless steel - Used in food, pharmaceutical or clean steam applications.
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Safety valve options and accessories

Levers Levers
Seating material
Levers Open and closed bonnets Bellows and diaphragm sealing
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Safety Valve Sizing
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Academic Manual AC/02/01

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Typical Steam Circuit

Make-up Water Feed Pump Feed Tank Condensate

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Steam flow meter.

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Vortex flow meter

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Specific Volume Vs Pressure of Saturated Steam

Pipes and Pipe SizingPipe material

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Pressure Reducing Station

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Single loop controller with chart recorder

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Distribute at High Pressure

How is Pipe Sized?

On the basis of:

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Pipe Thickness and Standard Sizes

Steam Pipe Sizing Chart (kg/h)

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Red Band - Heavy Grade Up to 4 m in length

Blue Band - Medium Grade Between 4 m - 7 m in length

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Pipeline Capacity and Pressure Drop

P2- P2 = F (Pressure Drop Factor) L

Pressure Factors for Pipe Sizing

Pressure Factors for Pipe Sizing

Pipe Sizing Example

195 m + 10% = 214 m equivalent pipe length

Boiler 7 bar g 289 kg/h

Heater Battery 6.6 bar g 270 kg/h

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Velocity Factor (y)

True Velocity x 2 y= Actual Volume

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Pipeline Capacity and Pressure Drop Factors

22 22 22 222 222 222 222 22 22 22 22 22 22 22 22 2 22 2 22 2 22 2 22 2 22 2 22 2

x = kg/h capacity y = m/s velocity with a volume of 1m3/kg

Pipeline Capacity and Pressure Drop Factors

22 22 22 222 222 222 222 22 22 22 22 22 22 22 22 2 22 2 22 2 22 2 22 2 22 2 22 2

x = kg/h capacity y = m/s velocity with a volume of 1m3/kg

Pipe Sizing Example

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True Velocity x 2 y= Actual Volume True Velocity 2. 2 22 = 22 . 2 True Velocity = 22 . m/s

Comparison of Results at 21m/s

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Pipe Alignment and Drainage

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Slug of water from condensate

Vibration and noise caused by waterhammer

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Relaying to Higher Level

30 - 50m Drain Points

Relay to high level

Steam Flow Flow

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