UTE Dead Sea

DSWPP-GT1

Report

Title:

LP steam velocity report

Client: UTE Dead Sea

Project: Dead Sea Works Power Station – Gas Turbine 1 (DSWPP-GT1)

Document Nº: 0331-CAL-ING-017-010-0002

Review: 0
Date: 10/07/2013

Prepared by:

María García Sánchez – Mechanical & Process Engineer (Electronic Signature)

Reviewed by:

Francisco Sánchez Molada - Mechanical & Process Lead Engineer (Electronic Signature)

Rafael Muriel Muñoz – Mechanical Engineer (Electronic Signature)

Approved by:

(Electronic Signature)
Iván Fuertes Pérez – Technical Project Manager

(Electronic Signature)
Cristina Chaza Chimeno- UDS Engineering Manager

This document is the property of UTE Dead Sea. Total or partial reproduction thereof, by any means, as well as distribution to third parties, without
the express written consent of UTE Dead Sea is strictly forbidden
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Review Control Sheet

Review Date Reason for the Review Prepared Reviewed Approved

0 10/07/2013 First issue MGS FSM IFP
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Index

1. Objective ................................................................................................................ 4
2. General description of the pipeline ...................................................................... 5
2.1. Normal operation ................................................................................................. 5
2.2. Startup & emergency............................................................................................ 5
3. Design criteria ........................................................................................................ 6
3.1. Steam conditions ................................................................................................. 6
3.2. Pipeline ............................................................................................................... 6
3.3. Thermal insulation ............................................................................................... 6
3.4. Drain pots ........................................................................................................... 6
4. Conclusions ............................................................................................................ 7
5. Appendix ................................................................................................................ 8
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1. Objective

This document is intended to explain the steam velocity considerations of the LP Steam export pipe,
which will be installed in Power Plant for the Dead Sea Works (DSW) at Sedom. The site is situated
next to the Dead Sea in Israel at 385 m below sea level.

The system is shown in the P&ID 88-30-01-108 “Main steam and by-pass system”.
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2. General description of the pipeline

The main function of the LP steam export pipe is to transport the low pressure steam from the
Alstom steam turbine to the terminal point TP07 from where is distributed to several consumers in
DSW Process Plants.
This pipe includes several safety-relief valves with silencers, one pneumatic check valves, one
motorized shut-off valve, one Annubar flowmeter, one manual shut-off valve for commissioning
and the required instrumentation for the proper operation of the plant.
The pipe has several drainages pots, where condensate is collected and produced mainly during
shut downs and start- ups but also during normal operation mode.

2.1. Normal operation

In normal operation, the low pressure steam flow is equal to 83.33 kg/s extracted from the Steam
Turbine last LP step at 130ºC and 1.7 barg.

2.2. Startup & emergency

In startup conditions, the steam is blow up to the atmosphere through the vents line at the outlet
of the Alstom steam turbine. The LP export steam line is preheated with superheated IP steam
through the bypass valve in order to minimize the low pressure steam condensation. When the
total flow of 20 kg/s the required export conditions are achieved and steam is delivered to TP07.

In an emergency situation, the maximum HP steam is diverted to the existing power plant and
therefore there is not production of low pressure steam.
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3. Design criteria

3.1. Steam conditions

• Alstom Steam Turbine outlet: 83.33 kg/s dry saturated steam (130º C – 1.7 barg)
• TP07: 83.33 kg/s dry saturated steam (125º C – 1.3 barg)

3.2. Pipeline

• Diameter: 48”
• Material: A53 GrB.
• Thickness: 12.87 mm
• Roughness: 0.0018”
• Length: 400 m

3.3. Thermal insulation

• Material: Mineral wool

• Density: 100 kg/m3
• Thermal conductivity coefficient: k=0.06 W/mK
• Thickness: 3”mm

3.4. Drain pots

• Diameter: 24”
• Number: 10
• Distance each other: 30-40m

The scheme of the system is shown in the appendix of guarantee case.

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4. Conclusions

The main purpose of the LP export steam header is to deliver low pressure steam to the terminal
point with the required steam characteristics and amount; 1.3 barg, 125º C and 300 tn/h.

Therefore the maximum allowable pressure drop along the pipe is equal to 0.4 bar and this goal is
achieved with the pipe selected (see point 3.2 above).

There is only one impact in the design of the pipeline, the steam velocity is over the recommended
value for saturated steam:

• Velocity at the Alstom Steam Outlet is equal to 51.31 m/s

• Velocity at the terminal point TP 07 is equal to 58.49 m/s

Nevertheless, this over velocity shall not be considered as an issue due to:

• Steam at 130ºC and 1.7 barg is a dry saturated steam, water title is 0.
• Low pressure drop in this large diameter along the pipeline with low density steam reduces the
formation of water droplets
• Thermal insulation guarantees a minimum heat loss along the pipeline and allows to arrive to
the terminal point with a slightly superheating (129.2 ºC)
• It has been installed several drain pots with large diameter in order to remove from steam
stream the possible water droplets.
• Pipeline supports are designed to withstand the vibrations that may transmit the steam
• The thickness of elbows, pipe change of direction, etc has been increased to resist better
possible erosion due to water droplets impact.
• It has been tried to install long radius elbows.
• Pipeline horizontal installation with 1% slope to the terminal point, reducing vertical pipes to
the required thermal loops
• There is not any standard that forces to comply with a maximum velocity if the required
pressure is risky.
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5. Appendix

Pipe-flo compressible reports of hydraulic calculation.

Appendix 1: Normal Operation. Guarantee case

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Appendix 1
Normal Operation. Guarantee case
 P: 1.43 bar g
T: 129.3 °C
~N{024}
e
sur
Pipe{033} res r
Ø: 48 in op p 34 ba 7}
d r 0 {02 sec
Flow: 83.33 kg/sec P: 0. Pipe in kg/
Vel: 58.49 m/sec d 48 3.33 /sec
Ø: 8
w: 7m
Flo 56.8

Flow: 83.33 kg/sec

} el:

Vel: 56.42 m/sec

2 8 V
~N{028} e{0 sec
Set @ 83.33 kg/sec Pip 8 in kg/
Flow: 83.33 kg/sec : 4 3.33 c
Ø :8 e

Pipe{026}
TotP: 1.361 bar g low m/s

Ø: 48 in
P: 1.339 bar g {027} baFr g l: 58
~N .368 V e
T: 129.2 °C 1 °C
P: 9.2
12
T: ~N{022}
P: 1.468 bar g
T: 129.3 °C

Pipe{021} ~N{023}
Ø: 48 in P: 1.452 bar g

Flow: 83.33 kg/sec

~N{016}

Vel: 55.44 m/sec

Flow: 83.33 kg/sec T: 129.3 °C

~N{013}
P: 1.502 bar g
Vel: 55.99 m/sec

T: 129.3 °C
Pipe{022}

~N{011}
~N{021}
Ø: 48 in
~N{012}

~N{005}
~N{006} Pipe{014}
Ø: 32 in
Control valve

Pipe{015}
Flow: 83.33 kg/sec

Ø: 32 in
~N{014}
Vel: 54.8 m/sec
Pipe{005} Pipe{009}

Pipe{012}
P: 1.534 bar g
Ø: 32 in Ø: 32 in

Ø: 32 in
T: 129.3 °C
Pipe{013}

Pipe{024}
Ø: 32 in

Pipe{017}

Pipe{006}

Pipe{011}
~N{018}

Pipe{016}
Ø: 48 in

Ø: 32 in

32 in

Ø: 32 in

Ø: 32 in
Pipe{010}
Pipe{007}
Pipe{008}

Ø: 32 in
Ø: 32 in
Ø: 32 in

Ø:
Pipe{019}

~N{007}
nodo 21 Ø: 48 in ~N{008} ~N{010}

~N{009}
Flow: 83.33 kg/sec
P: 1.526 bar g Flow: 83.33 kg/sec

Vel: 54.18 m/sec

T: 129.3 °C Vel: 54.46 m/sec
P: 1.559 bar g
T: 129.3 °C

Pipe{004}
~N{003}

Ø: 48 in
Flow: 83.33 kg/sec ~N{017}
Vel: 53.81 m/sec ~N{004} Set @ 27.77 kg/sec
P: 1.552 bar g
T: 129.3 °C
Pipe{031}

Pipe{003}
Ø: 48 in

Ø: 48 in
dP: 0.1 bar
Flowmeter

Flow: 83.33 kg/sec

Vel: 53.91 m/sec
Flow: 83.33 kg/sec
Vel: 51.59 m/sec
Pipe{002}
Ø: 48 in

Pipe{001}
~N{002} Ø: 48 in ~N{001}
P: 1.682 bar g Flow: 83.33 kg/sec set @ 1.71 bar g
T: 129.4 °C Vel: 51.31 m/sec Ptot: 1.71 bar g
P: 1.691 bar g

Lineup: <Design Case> PIPE-FLO Compressible 2007

System: LP exp and dump 48 prop 24.06 (normal) Flow: kg/sec
Date: 09/07/13 6:18 pm Pressure: bar g
Company: Size: in
Project: Velocity: m/sec
by: Length: m
Volume: m³