Block 10 Steam Distribution Steam Mains and Drainage Module 10.

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.

∆T
Q = kA Equation 2.5.1
ƒ

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 (m²)
∆T = Temperature difference across the material (K or °C)
ƒ = 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
Gradient 1:100 Steam
1:100
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 Condensate

Steam trap set

Fig. 10.3.3 Trap pocket properly sized

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 Pocket depth - d2
Up to 100 mm nb d1 = D Minimum d2 = 100 mm
125 - 200 mm nb d1 = 100 mm Minimum d2 = 150 mm
250 mm and above d1 ³ D / 2 Minimum d2 = D

Steam D Steam main

d2 d1

Float trap with

in-built sensor
Condensate return
Fig. 10.3.4

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.
o Water is dense and incompressible, so the ‘cushioning’ effect experienced when gases encounter
obstructions is absent.
o 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 Sagging in the line, perhaps due to failure of supports.
o Incorrect use of concentric reducers (see Figure 10.3.7) - Always use eccentric reducers with
the flat at the bottom.
o Incorrect strainer installation - They should be fitted with the basket on the side.
o Inadequate drainage of steam lines.
o Incorrect operation - Opening valves too quickly at start-up when pipes are cold.

Steam

Concentric
reducer Condensate Riser
Steam

Condensate
Steam

Condensate Strainer with

hanging basket

Fig. 10.3.6 Potential sources of waterhammer

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.
o Installing check valves after all steam traps which would otherwise allow condensate to run
back into the steam line or plant during shutdown.
o 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
Isolation Control
Drop leg valve valve

Strainer
Unit
heater

Isolation valve

Isolation valve
Trap set

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

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
Steam diameter Fall
velocity 1:40 Fall
Steam 30 m/s
1:100 Fall 15 m/s
velocity
30 m/s
30 - 50 m 15 m
15 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 . . .
o Incorrect chemical feedwater treatment and /or TDS control
o 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.

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 Pressure rating
o Capacity
o 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.
o 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
o 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 20°C, and an insulation efficiency of 80%
Steam -18°C
pressure Steam main size (mm) correction
bar g 50 65 80 100 125 150 200 250 300 350 400 450 500 600 factor
1 5 9 11 16 22 28 44 60 79 94 123 155 182 254 1.39
2 6 10 13 19 25 33 49 69 92 108 142 179 210 296 1.35
3 7 11 14 20 25 36 54 79 101 120 156 197 232 324 1.32
4 8 12 16 22 30 39 59 83 110 131 170 215 254 353 1.29
5 8 13 17 24 33 42 63 70 119 142 185 233 275 382 1.28
6 9 13 18 25 34 43 66 93 124 147 198 242 285 396 1.27
7 9 14 18 26 35 45 68 97 128 151 197 250 294 410 1.26
8 9 14 19 27 37 47 71 101 134 158 207 261 307 428 1.25
9 10 15 20 28 38 50 74 105 139 164 216 272 320 436 1.24
10 10 16 20 29 40 51 77 109 144 171 224 282 332 463 1.24
12 10 17 22 31 42 54 84 115 152 180 236 298 350 488 1.23
14 11 17 23 32 44 57 85 120 160 189 247 311 366 510 1.22
16 12 19 24 35 47 61 91 128 172 203 265 334 393 548 1.21
18 17 23 31 45 62 84 127 187 355 305 393 492 596 708 1.21
20 17 26 35 51 71 97 148 220 302 362 465 582 712 806 1.20
25 19 29 39 56 78 108 164 243 333 400 533 642 786 978 1.19
30 21 32 41 62 86 117 179 265 364 437 571 702 859 1 150 1.18
40 22 34 46 67 93 127 194 287 395 473 608 762 834 1 322 1.16
50 24 37 50 73 101 139 212 214 432 518 665 834 1 020 1 450 1.15
60 27 41 54 79 135 181 305 445 626 752 960 1 218 1 480 2 140 1.15
70 29 44 59 86 156 208 346 510 717 861 1 100 1 396 1 694 2 455 1.15
80 32 49 65 95 172 232 386 568 800 960 1 220 1 550 1 890 2 730 1.14
90 34 51 69 100 181 245 409 598 842 1 011 1 288 1 635 1 990 2 880 1.14
100 35 54 72 106 190 257 427 628 884 1 062 1 355 1 720 2 690 3 030 1.14
120 42 64 86 126 227 305 508 748 1 052 1 265 1 610 2 050 2 490 3 600 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 20°C, and an insulation efficiency of 80%
Steam -18°C
Steam main size (mm)
pressure correction
bar g 50 65 80 100 125 150 200 250 300 350 400 450 500 600 factor
1 5 5 7 9 10 13 16 19 23 25 28 31 35 41 1.54
2 5 6 8 10 12 14 18 22 26 28 32 35 39 46 1.50
3 6 7 9 11 14 16 20 25 30 32 37 40 45 54 1.48
4 7 9 10 12 16 18 23 28 33 37 42 46 51 61 1.45
5 7 9 11 13 17 20 24 30 36 40 46 49 55 66 1.43
6 8 10 11 14 18 21 26 33 39 43 49 53 59 71 1.42
7 8 10 12 15 19 23 28 35 42 46 52 56 63 76 1.41
8 9 11 14 16 20 24 30 37 44 49 57 61 68 82 1.40
9 9 11 14 17 21 25 32 39 47 52 60 64 72 88 1.39
10 10 12 15 17 21 25 33 41 49 54 62 67 75 90 1.38
12 11 13 16 18 23 26 36 45 53 59 67 73 81 97 1.38
14 12 14 17 20 26 30 39 49 58 64 73 79 93 106 1.37
16 12 15 18 23 29 34 42 52 62 68 78 85 95 114 1.36
18 14 16 19 24 30 36 44 55 66 72 82 90 100 120 1.36
20 15 17 21 25 31 37 46 58 69 76 86 94 105 125 1.35
25 15 19 23 28 35 42 52 66 78 86 97 106 119 141 1.34
30 17 21 25 31 39 47 51 73 87 96 108 118 132 157 1.33
40 20 25 30 38 46 56 70 87 104 114 130 142 158 189 1.31
50 24 29 34 44 54 65 82 102 121 133 151 165 184 220 1.29
60 27 32 39 50 62 74 95 119 140 155 177 199 222 265 1.28
70 29 35 43 56 70 82 106 133 157 173 198 222 248 296 1.27
80 34 42 51 66 81 97 126 156 187 205 234 263 293 350 1.26
90 38 46 56 72 89 106 134 171 204 224 265 287 320 284 1.26
100 41 50 61 78 96 114 149 186 220 242 277 311 347 416 1.25
120 52 63 77 99 122 145 189 236 280 308 352 395 440 527 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).
o 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.
o 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 Inverted bucket type
Fig. 10.3.14 Steam traps suitable for steam mains drainage

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.

Orifice size
500 12.5 mm

400
Steam leak rate kg /h

10 mm
300

200 7.5 mm

100 5 mm
3 mm
0
1 2 3 4 5 10
Steam pressure bar g
Fig. 10.3.15 Steam leakage rate through holes

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).
o Steam lines should be drained at regular intervals of 30 - 50 m and at any low points in the
system.
o Where drainage has to be provided in straight lengths of pipe, then a large bore pocket should
be used to collect condensate.
o If strainers are to be fitted, then they should be fitted on their sides.
o Branch connections should always be taken from the top of the main from where the driest
steam is taken.
o Separators should be considered before any piece of steam using equipment ensuring that dry
steam is used.
o Traps selected should be robust enough to avoid waterhammer damage and frost damage.

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 m³ /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 Safety
reducing valve
valve
DN25
stop valve
Steam at 280 kg /h of
7 bar g steam at 5 bar g
DN25 DN32
DN25 strainer stop valve
separator

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 ¨

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

10.3.14 The Steam and Condensate Loop