Block 10 Steam Distribution Pipe Expansion and Support Module 10.

Module 10.4
Pipe Expansion and Support

The Steam and Condensate Loop 10.4.1

Block 10 Steam Distribution Pipe Expansion and Support Module 10.4

Pipe Expansion and Support

Allowance for expansion
All pipes will be installed at ambient temperature. Pipes carrying hot fluids such as water or
steam operate at higher temperatures.
It follows that they expand, especially in length, with an increase from ambient to working
temperatures. This will create stress upon certain areas within the distribution system, such as
pipe joints, which, in the extreme, could fracture. The amount of the expansion is readily calculated
using Equation 10.4.1, or read from an appropriate chart such as Figure 10.4.1.

Expansion ( mm ) = L ∆T α Equation 10.4.1

Where:
L = Length of pipe between anchors (m)
∆T = Temperature difference between ambient temperature and operating temperatures (°C)
α = Expansion coefficient (mm /m °C) x 10-3

α) (mm /m °C x 10-3)
Table 10.4.1 Expansion coefficients (α
Temperature range (°C)
Material <0 0 - 100 0 - 200 0 - 300 0 - 400 0 - 500 0 - 600 0 - 700
Carbon steel 0.1% - 0.2% C 12.8 13.9 14.9 15.8 16.6 17.3 17.9 -
Alloy steel 1% Cr 0.5% Mo 13.7 14.5 15.2 15.8 16.4 17.0 17.6 -
Stainless steel 18% Cr 8% Ni 9.4 20.0 20.9 21.2 21.8 22.3 22.7 23.0

Example 10.4.1
A 30 m length of carbon steel pipe is to be used to transport steam at 4 bar g (152°C). If the pipe
is installed at 10°C, determine the expansion using Equation 10.4.1.
Expansion ( mm ) = L ∆T α
Where: L = 30 m
∆T = 152°C - 10 °C
∆T = 142°C
α in the range 0 - 200 = 14.9 x 10-3 mm m °C for carbon steel pipe
Expansion = 30 m x 142°C x 14.9 x 10 -3 mm m °C
Expansion = 63.5 mm
Alternatively, the chart in Figure 10.4.1 can be used for finding the approximate expansion of a
variety of steel pipe lengths - see Example 10.4.2 for explanation of use.
Example 10.4.2
Using Figure 10.4.1. Find the approximate expansion from 15°C, of 100 metres of carbon steel
pipework used to distribute steam at 265°C.
Temperature difference is 265 - 15°C = 250°C.
Where the diagonal temperature difference line of 250°C cuts the horizontal pipe length line
at 100 m, drop a vertical line down. For this example an approximate expansion of 330 mm is
indicated.

10.4.2 The Steam and Condensate Loop

Block 10 Steam Distribution Pipe Expansion and Support Module 10.4

Temperature difference °C
50 100 200 300 400 500
220
200
Example
10.4.2
Length of pipe (m) 100

50
40
30
20

10

0
10 2010030 40 50200 300 500 1 000 2 000
Expansion of pipe (mm)
Fig. 10.4.1 A chart showing the expansion in various steel pipe lengths at various temperature differences
Table 10.4.2 Temperature of saturated steam
bar g 1 2 3 4 5 7.5 10 15 20 25 30
°C 120 134 144 152 159 173 184 201 215 226 236

Pipework flexibility
The pipework system must be sufficiently flexible to accommodate the movements of the
components as they expand. In many cases the flexibility of the pipework system, due to the
length of the pipe and number of bends and supports, means that no undue stresses are imposed.
In other installations, however, it will be necessary to incorporate some means of achieving this
required flexibility.
An example on a typical steam system is the discharge of condensate from a steam mains drain
trap into the condensate return line that runs along the steam line (Figure 10.4.2). Here, the
difference between the expansions of the two pipework systems must be taken into account.
The steam main will be operating at a higher temperature than that of the condensate main, and
the two connection points will move relative to each other during system warm-up.

Steam Steam main Steam

Trap set

Condensate Condensate
Fig. 10.4.2 Flexibility in connection to condensate return line

The amount of movement to be taken up by the piping and any device incorporated in it can
be reduced by ‘cold draw’. The total amount of expansion is first calculated for each section
between fixed anchor points. The pipes are left short by half of this amount, and stretched
cold by pulling up bolts at a flanged joint, so that at ambient temperature, the system is stressed
in one direction. When warmed through half of the total temperature rise, the piping is
unstressed. At working temperature and having fully expanded, the piping is stressed in the
opposite direction. The effect is that instead of being stressed from 0 F to +1 F units of force,
the piping is stressed from -½ F to + ½ F units of force.

The Steam and Condensate Loop 10.4.3

Block 10 Steam Distribution Pipe Expansion and Support Module 10.4

In practical terms, the pipework is assembled cold with a spacer piece, of length equal to half the
expansion, between two flanges. When the pipework is fully installed and anchored at both
ends, the spacer is removed and the joint pulled up tight (see Figure 10.4.3).

L Spacer
piece

Position after cold draw Half calculated

expansion over
Neutral position length L
Hot position

Fig. 10.4.3 Use of spacer for expansion when pipework is installed

The remaining part of the expansion, if not accepted by the natural flexibility of the pipework
will call for the use of an expansion fitting.
In practice, pipework expansion and support can be classified into three areas as shown in
Figure 10.4.5.

Anchor Sliding support Expansion fitting Sliding support Anchor

point A point B point C point B point A
Fig. 10.4.4 Diagram of pipeline with fixed point, variable anchor point and expansion fitting
The fixed or ‘anchor’ points ‘A’ provide a datum position from which expansion takes place.
The sliding support points ‘B’ allow free movement for expansion of the pipework, while keeping
the pipeline in alignment.
The expansion device at point ‘C’ is to accommodate the expansion and contraction of the pipe.

Fig. 10.4.5 Chair and roller Fig. 10.4.6 Chair roller and saddle
Roller supports (Figure 10.4.5 and 10.4.6) are ideal methods for supporting pipes, at the same
time allowing them to move in two directions. For steel pipework, the rollers should be
manufactured from ferrous material. For copper pipework, they should be manufactured from
non-ferrous material. It is good practice for pipework supported on rollers to be fitted with a
pipe saddle bolted to a support bracket at not more than distances of 6 metres to keep the
pipework in alignment during any expansion and contraction.

10.4.4 The Steam and Condensate Loop

Block 10 Steam Distribution Pipe Expansion and Support Module 10.4

Where two pipes are to be supported one below the other, it is poor practice to carry the bottom
pipe from the top pipe using a pipe clip. This will cause extra stress to be added to the top pipe
whose thickness has been sized to take only the stress of its working pressure.
All pipe supports should be specifically designed to suit the outside diameter of the pipe concerned.

Expansion fittings
The expansion fitting (‘C’ Figure 10.4.4) is one method of accommodating expansion. These
fittings are placed within a line, and are designed to accommodate the expansion, without the
total length of the line changing. They are commonly called expansion bellows, due to the
bellows construction of the expansion sleeve.
Other expansion fittings can be made from the pipework itself. This can be a cheaper way to
solve the problem, but more space is needed to accommodate the pipe.
Full loop
This is simply one complete turn of the pipe and, on steam pipework, should preferably be fitted
in a horizontal rather than a vertical position to prevent condensate accumulating on the upstream
side.
The downstream side passes below the upstream side and great care must be taken that it is not
fitted the wrong way round, as condensate can accumulate in the bottom. When full loops are
to be fitted in a confined space, care must be taken to specify that wrong-handed loops are not
supplied.
The full loop does not produce a force in opposition to the expanding pipework as in some other
types, but with steam pressure inside the loop, there is a slight tendency to unwind, which puts
an additional stress on the flanges.

Flow Flow

Fig. 10.4.7 Full loop

This design is used rarely today due to the space taken up by the pipework, and proprietary
expansion bellows are now more readily available. However large steam users such as power
stations or establishments with large outside distribution systems still tend to use full loop type
expansion devices, as space is usually available and the cost is relatively low.
Horseshoe or lyre loop
When space is available this type is sometimes used. It is best fitted horizontally so that the loop
and the main are on the same plane. Pressure does not tend to blow the ends of the loop apart,
but there is a very slight straightening out effect. This is due to the design but causes no
misalignment of the flanges.
If any of these arrangements are fitted with the loop vertically above the pipe then a drain point
must be provided on the upstream side as depicted in Figure 10.4.8.

Side elevation

Flow Flow

Trap set
Fig. 10.4.8 Horseshoe or lyre loop

The Steam and Condensate Loop 10.4.5

Block 10 Steam Distribution Pipe Expansion and Support Module 10.4

Expansion loops

Welded bend
2W ∅
radius = 1.5∅

Welded joint
Fig. 10.4.9 Expansion loop

The expansion loop can be fabricated from lengths of straight pipes and elbows welded at the
joints (Figure 10.4.9). An indication of the expansion of pipe that can be accommodated by
these assemblies is shown in Figure 10.4.10.
It can be seen from Figure 10.4.9 that the depth of the loop should be twice the width, and the
width is determined from Figure 10.4.10, knowing the total amount of expansion expected from
the pipes either side of the loop.
Expansion from neutral position (mm)
25 50 75 100 125 150 175 200
400

300

200
Nominal pipe size (mm)

100
90
80
70
60

50

40

30

25
0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
W = width (metres)
Fig. 10.4.10 Expansion loop capacity for carbon steel pipes

10.4.6 The Steam and Condensate Loop

Block 10 Steam Distribution Pipe Expansion and Support Module 10.4

Sliding joint
These are sometimes used because they take up little room, but it is essential that the pipeline
is rigidly anchored and guided in strict accordance with the manufacturers’ instructions;
otherwise steam pressure acting on the cross sectional area of the sleeve part of the joint
tends to blow the joint apart in opposition to the forces produced by the expanding pipework
(see Figure 10.4.11). Misalignment will cause the sliding sleeve to bend, while regular
maintenance of the gland packing may also be needed.
Stay bolts

Pressure acts Gland

on this area packing

Movement due to
pipework expansion
Fig. 10.4.11 Sliding joint

Expansion bellows
An expansion bellows, Figures 10.4.12, has the advantage that it requires no packing (as does
the sliding joint type). But it does have the same disadvantages as the sliding joint in that pressure
inside tends to extend the fitting, consequently, anchors and guides must be able to withstand
this force.

Fig. 10.4.12 Simple expansion bellows

Bellows may incorporate limit rods, which limit over-compression and over-extension of the
element. These may have little function under normal operating conditions, as most simple
bellows assemblies are able to withstand small lateral and angular movement. However, in the
event of anchor failure, they behave as tie rods and contain the pressure thrust forces, preventing
damage to the unit whilst reducing the possibility of further damage to piping, equipment and
personnel (Figure 10.4.13 (b)).
Where larger forces are expected, some form of additional mechanical reinforcement should be
built into the device, such as hinged stay bars (Figure 10.4.13 (c)).
There is invariably more than one way to accommodate the relative movement between two
laterally displaced pipes depending upon the relative positions of bellows anchors and guides. In
terms of preference, axial displacement is better than angular, which in turn, is better than lateral.
Angular and lateral movement should be avoided wherever possible.

The Steam and Condensate Loop 10.4.7

Block 10 Steam Distribution Pipe Expansion and Support Module 10.4

Figure 10.4.13 (a), (b), and (c) give a rough indication of the effects of these movements, but,
under all circumstances, it is highly recommended that expert advice is sought from the bellows’
manufacturer regarding any installation of expansion bellows.
Guides

Axial movement
Short
distance Fixing point

Axial movement
Guides

Fig. 10.4.13 (a) Axial movement of bellows

Guides

Small
lateral
Limit rods Large
movement
lateral
movement

Medium Fixing point

distance
Large
lateral
Small
Limit rods movement
lateral
Guides movement

Fig. 10.4.13 (b) Lateral and angular movement of bellows

Hinged stay bars Small

angular
movement

Long Axial
distance movement

Small
angular
movement
Fixing point

Fig. 10.4.13 (c) Angular and axial movement of bellows

10.4.8 The Steam and Condensate Loop

Block 10 Steam Distribution Pipe Expansion and Support Module 10.4

Pipe support spacing

The frequency of pipe supports will vary according to the bore of the pipe; the actual pipe
material (i.e. steel or copper); and whether the pipe is horizontal or vertical.
Some practical points worthy of consideration are as follows:
o Pipe supports should be provided at intervals not greater than shown in Table 10.4.3, and run
along those parts of buildings and structures where appropriate supports may be mounted.
o Where two or more pipes are supported on a common bracket, the spacing between the
supports should be that for the smallest pipe.
o When an appreciable movement will occur, i.e. where straight pipes are greater than 15 metres
in length, the supports should be of the roller type as outlined previously.
o Vertical pipes should be adequately supported at the base, to withstand the total weight of the
vertical pipe and the fluid within it. Branches from vertical pipes must not be used as a means
of support for the pipe, because this will place undue strain upon the tee joint.
o All pipe supports should be specifically designed to suit the outside diameter of the pipe
concerned. The use of oversized pipe brackets is not good practice.
Table 10.4.3 can be used as a guide when calculating the distance between pipe supports for
steel and copper pipework.
Table 10.4.3 Recommended support for pipework
Nominal pipe size (mm) Interval of horizontal run Interval of vertical run
Steel Copper (metre) (metre)
bore outside diameter Mild steel Copper Mild steel Copper
15 1.2 2.4 1.8
15 1.8 3.0
20 22 2.4 1.2 3.0 1.8
25 28 2.4 0.5 3.0 2.4
32 35 2.4 1.8 3.7 3.0
40 42 2.4 1.8 3.7 3.0
50 54 2.4 1.8 4.6 3.0
65 67 3.0 2.4 4.6 3.7
80 76 3.0 2.4 4.6 3.7
100 108 3.0 2.4 5.5 3.7
125 133 3.7 3.0 5.5 3.7
150 159 4.5 3.7 5.5
200 6.0 8.5
250 6.5 9.0
300 7.0 10.0

The subject of pipe supports is covered comprehensively in the European standard

EN 13480, Part3.

The Steam and Condensate Loop 10.4.9

Block 10 Steam Distribution Pipe Expansion and Support Module 10.4

Questions
1. A DN100 Schedule 40 pipe carries steam at 10 bar g over a length of 80 m. If the pipe is
installed at 10°C, using Equation 10.4.1 and Table 10.4.1, by how much will it expand?
a| 291 mm ¨
b| 196 mm ¨
c| 352 mm ¨
d| 207 mm ¨

2. If the expansion of a pipe from installation to working temperature was 352 mm, what
length of spacer would be used in ‘cold drawing’ the pipe being installed?
a| 352 mm ¨
b| 704 mm ¨
c| 176 mm ¨
d| 88 mm ¨

3. A 100 m run of 80 mm pipe at 15 bar g is supported at its ends and three intermediate
points. It is trapped at intervals of 40 m. Noise and vibration often occurs at start-up.
What do you think is required to put things right?
a| Fit more supports at 3 m intervals ¨
b| Check that the steam traps are removing condensate properly ¨
c| Check that the steam main isolating valve is opened slowly ¨
d| All of the above ¨

4. A 150 mm steam pipe is to incorporate a fabricated expansion loop to take up 125 mm

of expansion. Using Figures 10.4.9 and 10.4.10, what should be the width and length of
the loop?
a| Width : 2.6 m; Depth : 5.2 m ¨
b| Width : 5.2 m; Depth : 2.6 m ¨
c| Width : 5.2 m; Depth : 10.4 m ¨
d| Width : 1.3 m; Depth : 2.6 m ¨

5. What is one advantage of a bellows expansion fitting over a horseshoe loop?

a| It is less expensive ¨
b| Its operating movement can be observed ¨
c| Fewer pipe supports are required ¨
d| It takes up less space ¨

6. Condensate from a heater battery operating at 3.8 bar g returns to a vented pump set
from where it is pumped through a carbon steel pipe to an atmospheric boiler feedtank
which is 85 m away. Using the chart in Figure 10.4.1, what will be the approximate pipe
expansion from an ambient temperature of 0°C?
a| 130 mm ¨
b| 200 mm ¨
c| 160 mm ¨
d| 100 mm ¨

Answers
1: d, 2: c, 3: d, 4: a, 5: d, 6: d

10.4.10 The Steam and Condensate Loop