Steam Mains and Drainage Module 10.

SC-GCM-76 CM Issue 3 Copyright 2006 Spirax-Sarco Limited

Block 10 Steam Distribution

Module 10.3
Steam Mains and Drainage

The Steam and Condensate Loop

10.3.1

Steam Mains and Drainage Module 10.3

Block 10 Steam Distribution

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.

 = N$

7
e

Equation 2.5.1

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 (m)
T = Temperature difference across the material (K or C)
= 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 European Standard EN 45510,
Section 10.1.14.
EN 45510 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

Steam

Gradient
1:100

1:100

Trap set

Trap set

Steam
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

Steam Mains and Drainage Module 10.3

Block 10 Steam Distribution

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

Condensate

Pocket
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
Up to 100 mm nb
d1 = D
125 - 200 mm nb
d1 = 100 mm
250 mm and above
d1 D / 2

Steam

Pocket depth - d2
Minimum d2 = 100 mm
Minimum d2 = 150 mm
Minimum d2 = D

Steam main

D
d2

d1

Float trap with

in-built sensor
Fig. 10.3.4

The Steam and Condensate Loop

Condensate return

10.3.3

Steam Mains and Drainage Module 10.3

Block 10 Steam Distribution

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.
Water is dense and incompressible, so the cushioning effect experienced when gases
encounter obstructions is absent.
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
o

Sagging in the line, perhaps due to failure of supports.

Incorrect use of concentric reducers (see Figure 10.3.7) - Always use eccentric reducers with
the flat at the bottom.

Incorrect strainer installation - They should be fitted with the basket on the side.

Inadequate drainage of steam lines.

Incorrect operation - Opening valves too quickly at start-up when pipes are cold.
Steam
Concentric
reducer

Riser

Condensate
Steam

Condensate

Steam
Condensate

Strainer with
hanging basket
Fig. 10.3.6 Potential sources of waterhammer

10.3.4

The Steam and Condensate Loop

Steam Mains and Drainage Module 10.3

Block 10 Steam Distribution

Eccentric reducer
Correct
Steam

Condensate
Incorrect
Steam

Concentric reducer

Condensate

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.
Installing check valves after all steam traps which would otherwise allow condensate to run
back into the steam line or plant during shutdown.
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

Steam Mains and Drainage Module 10.3

Block 10 Steam Distribution

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
Drop leg

Isolation
valve

Control
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.

Steam
velocity
30 m/s

Steam
velocity
15 m/s

1:100 Fall

30 - 50 m

Increase
in pipe
diameter Fall
1:40 Fall
30 m/s
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

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.

C
B

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

Capacity

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.
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:
PLQXWHV
[NJ
$YHUDJHFRQGHQVLQJUDWH
PLQXWHV
$YHUDJHFRQGHQVLQJUDWH NJ K
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.
For accurate means of calculating running losses from steam mains, refer to Module 2.12 Steam
consumption of pipes and air heaters. Alternatively, for quick approximations of running load,
Table 10.3.3 can be used which shows typical amounts of steam condensed each hour per 50 m
of insulated steam main at various pressures.

The Steam and Condensate Loop

10.3.9

Steam Mains and Drainage Module 10.3

Block 10 Steam Distribution

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 20C, and an insulation efficiency of 80%
Steam
-18C
Steam main size (mm)
pressure
correction
bar g
50
65
80
100
125
150
200 250
300
350
400
450
500
600
factor
1
2
3
4
5
6
7
8
9
10
12
14
16
18
20
25
30
40
50
60
70
80
90
100
120

5
6
7
8
8
9
9
9
10
10
10
11
12
17
17
19
21
22
24
27
29
32
34
35
42

9
10
11
12
13
13
14
14
15
16
17
17
19
23
26
29
32
34
37
41
44
49
51
54
64

11
13
14
16
17
18
18
19
20
20
22
23
24
31
35
39
41
46
50
54
59
65
69
72
86

16
19
20
22
24
25
26
27
28
29
31
32
35
45
51
56
62
67
73
79
86
95
100
106
126

22
25
25
30
33
34
35
37
38
40
42
44
47
62
71
78
86
93
101
135
156
172
181
190
227

28
33
36
39
42
43
45
47
50
51
54
57
61
84
97
108
117
127
139
181
208
232
245
257
305

44
49
54
59
63
66
68
71
74
77
84
85
91
127
148
164
179
194
212
305
346
386
409
427
508

60
69
79
83
70
93
97
101
105
109
115
120
128
187
220
243
265
287
214
445
510
568
598
628
748

79
92
101
110
119
124
128
134
139
144
152
160
172
355
302
333
364
395
432
626
717
800
842
884
1 052

94
108
120
131
142
147
151
158
164
171
180
189
203
305
362
400
437
473
518
752
861
960
1011
1062
1265

123
142
156
170
185
198
197
207
216
224
236
247
265
393
465
533
571
608
665
960
1 100
1 220
1 288
1 355
1 610

155
179
197
215
233
242
250
261
272
282
298
311
334
492
582
642
702
762
834
1 218
1 396
1 550
1 635
1 720
2 050

182
210
232
254
275
285
294
307
320
332
350
366
393
596
712
786
859
834
1 020
1 480
1 694
1 890
1 990
2 690
2 490

254
296
324
353
382
396
410
428
436
463
488
510
548
708
806
978
1 150
1 322
1 450
2 140
2 455
2 730
2 880
3 030
3 600

1.39
1.35
1.32
1.29
1.28
1.27
1.26
1.25
1.24
1.24
1.23
1.22
1.21
1.21
1.20
1.19
1.18
1.16
1.15
1.15
1.15
1.14
1.14
1.14
1.13

Table 10.3.3 Condensing rate of steam in 50 m of schedule 40 pipe - at working temperature (kg / h)
Note: Figures are based on an ambient temperature of 20C, and an insulation efficiency of 80%
Steam
-18C
Steam main size (mm)
pressure
correction
bar g
50
65
80
100
125
150
200 250
300
350
400
450
500
600
factor
1
2
3
4
5
6
7
8
9
10
12
14
16
18
20
25
30
40
50
60
70
80
90
100
120

10.3.10

5
5
6
7
7
8
8
9
9
10
11
12
12
14
15
15
17
20
24
27
29
34
38
41
52

5
6
7
9
9
10
10
11
11
12
13
14
15
16
17
19
21
25
29
32
35
42
46
50
63

7
8
9
10
11
11
12
14
14
15
16
17
18
19
21
23
25
30
34
39
43
51
56
61
77

9
10
11
12
13
14
15
16
17
17
18
20
23
24
25
28
31
38
44
50
56
66
72
78
99

10
12
14
16
17
18
19
20
21
21
23
26
29
30
31
35
39
46
54
62
70
81
89
96
122

13
14
16
18
20
21
23
24
25
25
26
30
34
36
37
42
47
56
65
74
82
97
106
114
145

16
18
20
23
24
26
28
30
32
33
36
39
42
44
46
52
51
70
82
95
106
126
134
149
189

19
22
25
28
30
33
35
37
39
41
45
49
52
55
58
66
73
87
102
119
133
156
171
186
236

23
26
30
33
36
39
42
44
47
49
53
58
62
66
69
78
87
104
121
140
157
187
204
220
280

25
28
32
37
40
43
46
49
52
54
59
64
68
72
76
86
96
114
133
155
173
205
224
242
308

28
32
37
42
46
49
52
57
60
62
67
73
78
82
86
97
108
130
151
177
198
234
265
277
352

31
35
40
46
49
53
56
61
64
67
73
79
85
90
94
106
118
142
165
199
222
263
287
311
395

35
39
45
51
55
59
63
68
72
75
81
93
95
100
105
119
132
158
184
222
248
293
320
347
440

41
46
54
61
66
71
76
82
88
90
97
106
114
120
125
141
157
189
220
265
296
350
284
416
527

1.54
1.50
1.48
1.45
1.43
1.42
1.41
1.40
1.39
1.38
1.38
1.37
1.36
1.36
1.35
1.34
1.33
1.31
1.29
1.28
1.27
1.26
1.26
1.25
1.22

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).
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.
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
Fig. 10.3.14 Steam traps suitable for steam mains drainage

Inverted bucket type

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.
Hole size
12.5 mm

Steam leak rate kg/h

500
400

10 mm

300
200

7.5 mm

100

5 mm
3 mm

0
1

The Steam and Condensate Loop

3
4
5
Steam pressure bar g
Fig. 10.3.15 Steam leakage rate through holes

10

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

o
o

10.3.12

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). Steam lines rising in the direction of flow should slope at not less
than 250 mm per 10 metres of pipe (1:40).
Steam lines should be drained at regular intervals of 30 - 50 m and at any low points in the
system.
Where drainage has to be provided in straight lengths of pipe, then a large bore pocket
should be used to collect condensate.
If strainers are to be fitted, then they should be fitted on their sides.
Branch connections should always be taken from the top of the main from where the driest
steam is taken.
Separators should be considered before any piece of steam using equipment ensuring that
dry steam is used.
Traps selected should be robust enough to avoid waterhammer damage and frost damage.

The Steam and Condensate Loop

Steam Mains and Drainage Module 10.3

Block 10 Steam Distribution

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 m /kg
a| 40 mm

b| 80 mm

c| 50 mm

d| 65 mm

The Steam and Condensate Loop

10.3.13

Steam Mains and Drainage Module 10.3

Block 10 Steam Distribution

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
reducing
valve

DN25
stop valve
Steam at
7 bar g
DN25
separator

DN25
strainer
Steam trap set

Safety
valve

280 kg /h of
steam at 5 bar g

DN32
stop valve

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