CHAPTER

Utility stations, steam and

condensate piping
16
16.1 STEAM PIPING
Steam—is water vapor, the gaseous phase of water, which is formed when water
boils, it is the visible mist of water droplets formed as this water vapor condenses
in the presence of cooler air.
Water boils at a temperature of 212°F/100°C (standard temperature and pres-
sure). At lower pressures, water boils at temperatures lower than 212°F/100°C.
If heated further it becomes “Superheated steam.” The energy required to turn
water into its gaseous form is called the “enthalpy of vaporization.” Steam is pro-
duced by heating a boiler via burning coal, gas, and other fuels. Water vapor that
includes water droplets is described as wet steam. As wet steam is heated further,
the droplets evaporate, and at a high enough temperature (which depends on the pres-
sure), all the water evaporates and the system is in vapor-liquid equilibrium.
Superheated steam is steam at a temperature higher than its boiling point for the
pressure which only occurs where all the water has evaporated or has been removed
from the system. Steam tables contain thermodynamic data for water/steam and are
used by engineers in the design and operation of equipment where thermodynamic
cycles involving steam are used. Thermodynamic phase diagrams for water/steam,
such as a temperature-entropy diagram or a Mollier diagram may be used. Steam
charts are also used for analyzing thermodynamic cycles. Layout of steam piping
must take into consideration thermal growth. As piping gains temperature, it also
gains in length (thermal expansion).

The Engineer’s Guide to Plant Layout and Piping Design for the Oil and Gas Industries.
https://doi.org/10.1016/B978-0-12-814653-8.00016-3
381
# 2018 Elsevier Inc. All rights reserved.
382 CHAPTER 16 Utility stations, steam and condensate piping

Initial temperature
(°C)

Temperature expansion (mm / m)

4
−20
0
10
3 20
30
40

engineeringtoolbox.com
0
0 50 100 150 200 250 300
Final temperature (°C)
Expansion tables for carbon steel pipe

Thermal expansion of steam piping can be absorbed by the use of loops and
L-shaped, U-shaped and Z-shaped loops.

These expansion legs absorb the longitudinal expansion and contraction in the line
due to temperature changes. We will go into greater details of expansion and stresses
in Chapter 19. Generation of steam in the piping system causes a buildup of conden-
sate that must be removed from the system.
 16.2 Drip legs 383

STEAM PIPING
Take offs for subheaders must always be taken from the top of the steam header.

Valve to be in horizontal to prevent

Condensate build up downstream of valve

Branch
Steam flow

Steam header

Drawing showing steam header take offs

16.2 DRIP LEGS

Steam piping systems contain condensate which must be removed. Condensate can
be removed from the system by the use of drip legs and steam traps

Steam header

Reinforcing pad
Pot size when req’d
to suit

75 mm
To steam trap
located accessible
from platform or grade
Plug
Valve sizes to suit

Steam main

Condensate
Liquid expansion to return line
steam trap
Condensate to drain
384 CHAPTER 16 Utility stations, steam and condensate piping

D Steam main Steam

d
d2 Drain
pocket
Float trap Check valve

Strainer

Sight glass

Condensate

Main diameter D Pocket diameter d1 Pocket depth d2

Up to 100 mm d1 = D Minimum d2 = 100 mm
125 – 200 mm d1 = 100 mm Minimum d2 = 150 mm
250 mm and above d1 = D/2 Minimum d2 = D

Drip leg schematic

Photo of Drip Leg on Steam Line

 16.3 Steam traps 385

DRIP LEGS COLLECT CONDENSATE FROM THE STEAM LINE

"A" = 6" FOR 10" & 12" DIA
= 8" FOR 14",16" & 18" DIA
= 10" FOR 20" & 24" DIA
AP
P TR 150 NOM BORE +8"
RA TO 90
"B" =
2
T
TO P

75
CA EG AP
D IP L TR
EL DR E "A" TO
W SIZ 80
P
OW 5 CA
BL F 17 LD
"B" WE
4" OF
0 3/ OW
15 BL W
4" FF LO
3/ O "B F
3/4 OF
Drip leg for lines Drip leg for lines 2 ½' – 8" Drip leg for lines 10" – 24"
2" & below

They are located at all the low points on a steam system and at intervals along the
steam headers.
Drip legs on main steam header should be located at intervals of between 1000 and
2000 /30–60 m. it is also preferable to slope the steam header to allow drainage
although there is enough pressure in the header to move the condensate without
sloping.
Drip legs should also be located before a rise in elevation of the steam line, for
example, before the vertical leg of a steam expansion loop.

Drip leg Flow

16.3 STEAM TRAPS

Steam traps are used to remove condensate from steam headers, steam subheaders,
upstream at control stations and expansion loops, heating coils, condensing equip-
ment, reboilers, steam tracing manifolds, and steam tracing lines. The function of
the steam trap is to remove both air and noncondensable gases from the steam sys-
tem. If air was not removed from the system you would get uneven heating, increased
corrosion, at the worst, it would prevent steam from entering the equipment and heat
transfer would not be possible. The steam trap is designed to close in the presence of
steam and drain the condensate. As the steam condenses into a liquid, it gives up its
latent heat. The latent heat results in lb, for lb the steam releasing more energy than
386 CHAPTER 16 Utility stations, steam and condensate piping

the water. The steam traps purpose is to prevent the steam leaving the system before
it gives up its latent energy. As steam gives up its latent heat it changes state from
vapor to liquid. The liquid is known as condensate. If this condensate is not removed
then it will result in incomplete heat transfer and possible water hammer. To enable
the collection of the condensate, a drip leg must be located in the steam line. The
drip legs must be located at every low point in the steam system. On long horizontal
runs of pipe it is necessary to provide drip legs and steam traps at intervals along
the pipe.
There are three categories of steam traps

• Mechanical (Ball Float, Inverted Bucket)

• Thermodynamic (Impulse, Controlled Disk)
• Thermostatic (Temperature Sensitive Traps)

BALL FLOAT TRAPS

Air cock

Ball float traps schematic Ball float trap photo

INVERTED BUCKET TRAP

Inverted bucket traps are the most reliable type of trap—the lever system opens the
valve against pressure.
Vent

Outlet

Inlet

Inverted
bucket

Inverted bucket trap schematic Photo of inverted bucket trap

 16.3 Steam traps 387

THERMODYNAMIC STEAM TRAP

Thermodynamic steam traps operates by the dynamic effect of flash steam as it
passes through the trap.

Thermodynamic steam trap schematic Thermodynamic steam trap photo

THERMODYNAMIC STEAM TRAP

There are two types of thermostatic static and balanced pressure

Bi-metallic thermodynamic steam traps

388 CHAPTER 16 Utility stations, steam and condensate piping

STEAM TRAP SELECTION

Trap Type Float & Thermostatic Inverted Bucket Thermostatic Thermodynamic

Response Fast Moderate Moderate Slow

Air venting Medium/High Low High Low

Drip legs
Drip legs Drip legs Drip legs
Applications Process equipment
Process equipment Process equipment tracing
tracing

Capacity High High Low Low

Maintenance Moderate Moderate Easy Easy

Relative cost Medium/High Medium/Low Low Low

Capacity High High Medium Low

< Freezing > Freezing

Inverted Differential
Characteristic F&T Disc Thermostatic
Bucket Controller
A Method of Operation Intermittent Continuous Intermittent Intermittent Continuous
B Energy conservation (time in service) Excellent Good Poor Fair Excellent

C Resists wear Excellent Good Poor Fair Excellent

D Resists corrosion Excellent Good Excellent Good Excellent
E Resists hydraulic shock Excellent Poor Excellent Poor Excellent
F Vents air and CO2 at steam temperature Yes No No No Yes
(0.02
G Vents air at very low pressure (1/4 psig) bar) Poor Excellent NR Good Excellent

H Handles start-up air loads Fair Excellent Poor Excellent Excellent

I Operates against back pressure Excellent Excellent Poor Excellent Excellent

J Resists damage from freezing Good Poor Good Good Good

K Can purge system Excellent Fair Excellent Good Excellent

L Performs on very light loads Excellent Excellent Poor Excellent Excellent
M Responds to slugs of condensate Immediate Immediate Delayed Delayed Immediate
N Handles dirt Excellent Poor Poor Fair Excellent
O Comparative physical size Large Large Small Small Large
P Handles ‘flash steam’ Fair Poor Poor Poor Excellent
Q Mechanical failure (open–closed) Open Closed Open Open,Closed Open
First choice Alternative
 16.5 Steam tracing 389

16.4 STEAM CONTROL SETS

All low points in a steam line must be trapped, this include control stations.
A drip leg must be located upstream of the control valve.

16.5 STEAM TRACING

Steam tracing is used for the freeze protection of pipelines. It is used as an alterna-
tive to electrical tracing. The steam consumption necessary to enable this freeze pro-
tection is dependent on the following:
• Contact between the tracer line and product line
• Line temperature
• Ambient temperature
• Wind speed
• Insulation
• Lengths, temperature, and pressure drop along the tracer lines
390 CHAPTER 16 Utility stations, steam and condensate piping

Steam tracing lines are small diameter pipes that are a dedicated system fed from a
steam supply header. Each tracer must be terminated with a steam trap. To calculate
the size of a steam tracer header you must calculate the total cross section of all the
tracers and then calculate the header size to allow for the same flow area. The rate of
condensate of the tracer depends upon the length of tracer that is in contact with the
process line. Line expansion of the steam tracer must also be taken into consider-
ation. The thickness of insulation is determined by the line temperature and tracer
size must be allowed for. Tracers should be run parallel to and set against the under-
side of the pipe that is to be heated. Steam supply to the piping arrangement must be
fed to the highest point to allow for drainage, and assist gravity flow to condensate
traps. A steam trap is not required at every low point of the tracer system, but must be
provided at the end of the tracer. When looping tracers around flanges make sure that
unions are provided. Only run one tracer line to each trap.

Tracer feed

Spare
Steam

½''

¾''
Supply line

Isometric limit
Steam header (Typ.)
½'' ½'' ½''

3'' Manifold
½'' ½''

Ground or
condensate
recovery, as
required ½'' ¾''
Drain
½'' Steam trap

Unnecessary when
condensate is not
recovered
 16.6 Jacketed lines 391

16.6 JACKETED LINES

Jacketed piping is also used for process heating requirements of a pipeline.
• Jacketed Lines are used for the continuous heating of a process line
• Jacketed line can be fed by steam or hot oil or glycol
• Jacketed lines are fabricated in flanged sections

Core-size flange
Heating fluid

Process Process

Heating fluid

Jacket-size flange

Schematics showing jacket at flange and sections of jacketed pipework

392 CHAPTER 16 Utility stations, steam and condensate piping

LNG lines use jacketed lines to keep them cold. They do not use steam or oil they use
vacuum insulation.

Outer VJP jacket

Low thermal conductivity

radial supports

Annular space with molecular

sieve and getters
Vacuum

Inner pipe

Super insulation

Section through Jacketed Line

 16.7 Utility hose stations 393

16.7 UTILITY HOSE STATIONS

Plant air header
Nitrogen if required
Water header

Steam header
Pipe support

Piperack column

Hose rack

Hose connection

Elevation 1200 above grade

Isometric drawing of utility station

394 CHAPTER 16 Utility stations, steam and condensate piping

16.8 SAFETY SHOWERS

Safety showers and eyewashes are required everywhere that there is a chance of com-
ing into contact with chemicals or hazardous products.
29-3/4''
756 mm

11''
279 mm

Supply
3 1-1/4” IPS 27-5/8''
702 mm

Ø9''
Ø229 mm
Ø3/8''
3× 10-3/16''
Ø10 mm
259 mm
30''
Dust cover
(open position)
Ø8'' B.C.
Ø203 mm 83-3/4''
2127 mm
Mounting detail
62-1/2''
L-Strainer 1586 mm

42-3/8
1077 mm

SP220SS Waste 1-1/4'' IPS

OPTIONAL
Floor line
6-3/4''
171 mm
 16.8 Safety showers 395

Eyewash & Safety Shower signs

Eyewash

Eyewash and Safety Shower