6.

0 STEAM/CONDENSATE LINES

PREFACE

This section covers the line sizing criteria for steam and condensate lines including vacuum
systems, steam networks, flashing condensate systems and the use of linesize program of
PPS (Pressure Profile Suite).

6.1 STEAM LINES

Steam lines are sized on the basis of pressure drop and velocity considerations. For larger
sizes (12" and over), velocity is usually the controlling factor.

Recommended design velocities are plotted on Chart D 3.1. Pressure drops when required
will be calculated using the chart and formulae for Process Vapor Lines per Section 5. For
vacuum systems where the pressure drop is greater than 10% of the source operating
pressure, the formulae for compressible (gases) flow from Chart B 2.1 must be used.

Computer program Linesize of Pressure Profile Suite (PPS) can be used for steam line sizing.
Linesize program has built-in steam property correlations incorporating specific volume,
viscosity, and density. The density and viscosity correlation of steam are estimated by the
Method of Keenan & Keyes for temperature <651°F (344°C) and pressure £ 2204 psia (152
bara or 15.2MPa abs). In addition, the correlation is only valid for specific volume ³ 0.16 ft3/lb
(0.01 m3/kg) which corresponds to density £ 6.24 lbs/ft3 (100 kg/m3). For Steam temperature
from 651°F (344°C) to 1472°F (800°C) and pressure from 2204 psia (152 bara) to 14504 psia
(1000 bara), the equations in ASME Steam Table 5th Edition are used. While making an input
of maximum allowable velocities, Chart D 3.1 should be used. Erosion velocities should not
be exceeded in any case.

6.2 ILLUSTRATIVE PROBLEMS

Determine the size of a steam lead line (assume Sch. 40) which delivers 12,000 lbs/hr. of 150
lb. saturated steam to a turbine; find the pressure drop in psi/100 ft for this line.

6.2.1 Graphical Method

Select a line size on the basis of velocity from Chart D 3.1.

3 3
Q( ft ) = M ( Lbs ) ´ v( ft )
hr hr Lb
For 150 lb. saturated steam, v = 2.75 ft3/lb
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3DG-M11-F0001-003 PAGE 1 OF 18
 Q = 12,000 x 2.75 = 33,000 ft3/hr
Follow Q = 33,000 vertically to its intersection with the recommended design velocity
line (B) for 100 to 200 psig steam lead lines. The next largest pipe line to this
intersection is 4" (Sch. 40).

6.2.2 Formula Method

Check the selected line for pressure loss.

6.32M
Re = (Chart B 2.1)
mD
6.32 ´ 12,000
Re = = 1,256,000
0.015 ´ 4.026

f = 0.0167 (Chart B 4.1)

f ´M2
Dp = 0.00336 ´ (Chart B 2.1)
rD 5

0.0167 ´ (12,000) 2
Dp = 0.00336 ´
0.364 ´ 1058

Dp = 21.0 Psi/1000 ft = 2.1 psi/100 ft

Note: If the equivalent length of the line were in excess of 700 feet, then
the formula for compressible fluids would have to be used.

Pressure Drop and Velocity Using Linesize Program

Pressure drop for 4 inch Sch. 40 pipe as per computer output in

Attachment 6-1
Pressure Drop = 2.133 psi/100 ft
Velocity = 105 ft/sec

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STEAM CONDENSATE LINES

3DG-M11-F0001-003 PAGE 2 OF 18
6.2.3 Sonic Velocity Method for Vacuum Steam Lines

1500 lb/hr. of stripping steam (originally saturated at 400°F) is fed into a vacuum stripping
tower operating at 2.0 psia. Determine the most reasonable line size (Sch. 40) leading from
the steam flow control valve to the tower.

Solution by Manual Method:

The steam flowing through this line will be at 2 psia and 310°F (is enthalpic expansion).

n ´T
Vc = 41 ´ (Chart D 4.1)
G
Cp = 8.29 Btu/lb-mol°R
Cv = 8.29 - 1.98 = 6.30
n = Cp/Cv = 8.29/6.30 = 1.32
T = 460 + 310 = 770°R
G = 18/29 = 0.62
Vc = 1660 ft/sec
(1500) Lb (229) ft 3 3
Flow rate is ´ = 95.42 ft
(3600) sec Lb sec
3
95.42 ft
Flow area, A = sec = 0.0575 ft 2
1660 ft
sec
Area of 3" Sch. 40 is 0.0513 ft2
Area of 4" Sch. 40 is 0.0884 ft2

Therefore, 4" Sch. 40 is the minimum satisfactory size for this service.

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STEAM CONDENSATE LINES

3DG-M11-F0001-003 PAGE 3 OF 18
6.3 STEAM NETWORK ANALYSIS

Steam Networks are analyzed by methods similar to those used for water networks. The
computer program used is Steamnet. This program determines steady state flow and
pressure conditions in a steam distribution network. The steam is assumed to be saturated
vapor, but a procedure is available to account for superheat in specified lines. The input
includes a description of network configuration, length, diameter and roughness of lines,
locations and pressure of steam supply points, location and magnitude of steam demand
points, and location of valves and steam turbines. Steam may be specified in either lbs/hr or
MBtu/hr. The output includes flow in each line and pressure at each junction, pressure drop
and mean flow velocity for each line. A set of minimum and maximum values for pressure,
velocity and pressure drop is part of the output. The input format allows cases to be run
consecutively. Steamnet is particularly useful in determining the effect of demand or load
changes on conditions in the overall network or in particular parts of the network. For further
information please refer to the User's Manual. The User’s Manual is available on-line.
Support is also available from the Project Engineering Staff in Houston.

6.4 STEAM CONDENSATE LINES

The sizing of steam condensate return lines differs in those areas where the line has to handle
flash steam and liquid condensate. It is common to encounter condensate in the liquid phase
either up to the steam trap or to the level control valve of the condensate pot. These lines are
sized as liquid lines. Use Section 2.1 for sizing such lines. Downstream of the trap or the
control valve, condensate flashes into steam. The specific volume of flash steam is many
times greater than the specific volume of condensate. These lines are, therefore, sized as two
phase steam and liquid condensate lines.

While making a judgement about the type of flow, estimate whether fluid pressure is above the
saturation pressure corresponding to the temperature. If above, it is single phase liquid. If
not, it is two phase flow.

The elevation of the steam trap or the condensate pot level control valve has to be properly
specified so that single phase liquid flow is assured up to these points. See Section 6.4.2 for
flash calculations. Use Section 6.4.3 for sizing lines with flashing condensate.

6.4.1 Condensate Loads

Steam consumption and corresponding condensate generation from heat exchangers are
normally specified in the PFDs, heat exchanger data sheets or utility balance diagrams. Some
process packages show the steam required for steam coils in tanks or for heating steam
jackets. When these figures are available they should be used. There are many instances
when such data is not available. In such cases steam consumption and condensate loads
must be estimated. Methods for calculating condensate loads are illustrated below.
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3DG-M11-F0001-003 PAGE 4 OF 18
6.4.2 Calculating Condensate Loads

The two basic formulas for estimating condensate loads are:

Q = UAdt and Eq. 6-1

Q = W x SH x (T2 - T1) Eq. 6-2

where Q = Quantity of Heat (Btu/hr)

U = Heat Transfer Coefficient (Btu/hr-ft²-ºF)
A = Area through which heat flows (ft²)
dt = Temperature difference between steam and secondary
fluid (ºF)
W = Weight of material being heated (secondary fluid, not
steam) (lbs/hr)
SH = Specific Heat of this material (secondary fluid)
(Btu/lb-ºF)
T2 = Final Temperature of material (secondary fluid) (ºF)
T1 = Initial Temperature of material (Secondary fluid) (ºF)

In both cases, dividing by L the Latent Heat at operating pressure (Enthalpy of

Evaporation, Btu/lb) will give weight flow rate of steam condensed.
If the rate of generation of steam condensate is C, lbs/hr, then

UAdt
C= from Eq. 6-1 or
L
W ´ SH ´ (T2 - T1 )
C= from Eq. 6-2
L
L = Btu
Lb

When the material being heated (but not evaporated) is water, then
W ´ (T2 - T1 )
C= Eq. 6-3
L

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3DG-M11-F0001-003 PAGE 5 OF 18
 Since specific heat of water = 1.0, it is often convenient to approximate, and use
1000
(= 909) as the Latent Heat in Btu/lb, which gives
1 .1

W ´ (T2 - T1 ) ´ 1.1
C= Eq. 6-4
1000

In US units where 1 gpm of water is roughly 500 lb/hr, this transforms to

Pounds/hour condensate

Water ( gpm) ´ (T2 - T1 ) ´ 1.1

C= Eq. 6-5
2

When heating oils having SH = 0.5, then Pounds/hour condensate

Oil flow( gpm) ´ (T2 - T1 ) ´ 1.1

C= Eq. 6-6
4

When heating air with Air Heaters, the Condensate Load C (lbs/hr) is given by
cfm ´ 60 ´ (T2 - T1 ) Specific Heat of Air
C= ´ Eq. 6-7
L Specific Volume of Air
where cfm is air flow in cubic feet per minute. Specific heat is in Btu/lb-ºF and
specific volume is in ft3/lb.
At ambient temperatures of 60ºF and pressure 14.7 psia, the specific volume of air
is approximately 13.2 ft3/lb and the Specific Heat at constant pressure is about
0.24 Btu/lb-ºF. So,
cfm ´ 60 ´ (T2 - T1 ) ´ 0.24 cfm ´ (T2 - T1 ) ´ 1.09
C= = Eq. 6-8
13.2 ´ L L

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3DG-M11-F0001-003 PAGE 6 OF 18
 Using the conservative approximation as before of
1000
L= (= 909) , the formula becomes
1 .1
cfm ´ (T2 - T1 ) ´ 1.09 ´ 1.1 cfm ´ (T2 - T1 )
C= =
1000 833

This is often rounded off to

cfm ´ (T2 - T1 )
C= Eq. 6-9
800

The above are simplified methods for estimating condensate loads and should be used for
preliminary estimates.

It is necessary to estimate the warmup and running loads for the proper design of a
condensate system. For preliminary estimates the tables in Attachment 6-4 and Spirax Sarco
Steam Needs Analysis Program can indirectly be used to estimate loads. See Attachment 6-5
for a list of options and Attachment 6-2 for an example. All too often the condensate loads of
steam headers and laterals are not included in the process package and have to be estimated.
Spirax Sarco's Steam Need Analysis Program can be used.

For a rigorous analysis, heat loss calculations from insulated pipes should be done. These
take into account steam temperature, ambient temperature, wind velocity, insulation thickness,
insulation thermal conductivity, pipe diameter and pipe wall thickness. The heat loss divided
by latent heat of steam gives the required steam load. This is then the rate of condensate
generation.

6.4.3 Condensate Flash

High pressure condensate is formed at the same temperature as the high pressure steam
from which it is condensed (unless it is subcooled). In the process the latent heat (Enthalpy of
Evaporation) is removed. When this condensate is discharged to a lower pressure, the energy
it contains is greater than it can hold while remaining as liquid water. The excess energy re-
evaporates some of the water as steam at the lower pressure. In process, power and
industrial plants this normally happens downstream of the steam trap or level control valve of a
condensate pot flowing either to a flash drum or to a deaerator.

The flash percentage by weight can be estimated by the relation.

SH - SL
% Flash = ´ 100 Eq. 6-10
L
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3DG-M11-F0001-003 PAGE 7 OF 18
 Where:

SH = enthalpy of condensate at the steam trap pressure, Btu/lb

SL = enthalpy of condensate at the flash drum pressure, Btu/lb

L = latent heat (heat of evaporation) in the steam at the flash drum pressure
to which the condensate has been discharged, Btu/lb

As an illustration consider condensate at 100 psig and enthalpy of 308.8 Btu/lb is discharged
to atmospheric pressure (0 psig). Its enthalpy drops to 180 Btu/lb.

The percentage of the condensate that will flash to steam is computed as follows:
SH - SL
% Flash Steam = ´ 100
L

308.8 - 180
= ´ 100
970.3

= 13.3%

For quick estimates, Chart A 5.5 can be used for determining percent flash.

As explained below, PPS can also be used for steam condensate flashing calculation.

Click the Condensate Flashing option in the PPS main window, the Steam Condensate
Flashing dialog box will appear. Enter the Upstream Pressure (114.7 psia in this illustration
example), Flowrate (10000 lb/hr), and Downstream Pressure (14.7 psia), then click the Calc
button, the results displayed on the right as shown on the Attachment 6-6, in addition to the %
Flash shown (13.28%).

It also displays the liquid mass flowrate, liquid density, liquid viscosity, vapor flowrate, vapor
density, vapor viscosity, and surface tension, etc, when Linesize button is clicked, those liquid
and vapor properties are transferred to the Linesize Line Detail screen.

If the min. Nominal Diameter (6” in this case) is entered and the Calculate button is clicked,
the steam condensate two-phase flow calculation will be performed.

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3DG-M11-F0001-003 PAGE 8 OF 18
6.4.4 Sizing Condensate Lines

Flashing condensate lines (downstream of steam traps and control valves) should be sized for
two-phase flow.

For preliminary and conservative estimates, the degree of flash can be estimated at the
discharge (low pressure) end. The line can then be sized presuming that the entire two-phase
line has the same degree of flash as at the exit.

For rigorous analysis the pipe length should be broken into smaller segments and starting
backwards from the flash tank the degree of flash calculated for each segment and the
corresponding pressure drop estimated. Excess pressure shall be dropped across the trap or
the control valve.

Flashing condensate lines are best sized using computer programs. However, if these are not
available and the trap upstream pressure is above 60 psig, Chart C 5.1 from Spirax Sarco can
be used.

The degree of flash should be estimated prior to running the program. Attachment 6-3
illustrates the use of Linesize program for sizing condensate line. Attachment 6-6 illustrates
the use of PPS Condensate Flashing option to perform flash calculation and the subsequent
Linesize calculation. Since high velocities can have adverse effects on piping systems,
especially valves, tees, elbows, and bends, erosion velocities should not be exceeded.
Erosion velocity limits for flashing condensate lines are:

60
V £
r

Where r is the density of mixture in lbs/ft3

V is the velocity in ft/sec.

WL + WG
r=
WL WG
+
r L rG
Where
W = Weight flow, lbs/hr
r = Phase density, lbs/ft3 at flowing conditions
L = Liquid phase (water)
G = Gaseous phase (steam)
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3DG-M11-F0001-003 PAGE 9 OF 18
When performing a rigorous analysis, pressure drop in both horizontal and vertical sections
should be considered. Separate two phase correlations should be used for each.

Besides estimation of pressure drop and flow regimes at design flow, computer runs should be
made for turndown flow. The intent should be to avoid slug flow at all flow rates. Alternate
line sizes should be considered if slug flow is predicted under any alternatives.

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3DG-M11-F0001-003 PAGE 10 OF 18
 Attachment 6-1

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3DG-M11-F0001-003 PAGE 11 OF 18
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3DG-M11-F0001-003 PAGE 12 OF 18
 Attachment 6-2

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3DG-M11-F0001-003 PAGE 13 OF 18
 Attachment 6-3

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3DG-M11-F0001-003 PAGE 14 OF 18
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3DG-M11-F0001-003 PAGE 15 OF 18
 Attachment 6-4
DRAINING STEAM MAINS

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3DG-M11-F0001-003 PAGE 16 OF 18
 Attachment 6-5

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3DG-M11-F0001-003 PAGE 17 OF 18
 Attachment 6-6

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3DG-M11-F0001-003 PAGE 18 OF 18