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INTERNAL TRAINING
FOR
STEAM PIPING WORK
TAIKISHA VIETNAM ENGINEERING
TERUMO BCT PROJECT
VERSION 1
OCTOBER 2013
PURPOSE
Give critical knowledge to staffs
A Saturated Steam Property
A 1. Absolute Pressure and Gauge Pressure
A 2. Saturated Steam Property
B Steam pipe expansion
B 1. Expansion amount
B 2. Long Pipe/Main Pipe Expansion absorbtion (Expansion Joint, Expansion Loop, Fixing and Guiding)
* Expansion Joint
* Expansion Loop
* Fixing
* Guiding
B 3. Branch ( 2 elbow, 3 elbow ..), it depends on lengh from fixed point
B 4. Steam Piping arround Equipment
C Steam condensate
C 1. Steam condensate
C 2. Steam trap selection, location; Steam drain pipe inside of hot well tank; Reducer, valve direction
C 3. Insulation of Steam trap
C 4. Flash Steam
C 5. Flash tank
D Pressure reducing valve
Steam Pressure reducing valve
E Steam Pressure Gauge
Steam Pressure Gauge
ST-01-01 TERUMO BCT
STEAM PIPING
TRAINING CONTENTS
ST-01-02 A-1
STEAM PIPING
ABSOLUTE PRESSURE and GAUGE PRESSURE
Absolute pressure and gauge pressure
Gauge pressure. ..Gauge pressure is the pressure as indicated by a gauge. It is important to understand that
gauges are calibrated to read zero at atmospheric pressure. Gauges measure only the difference in
pressure between the total pressure of the fluid in the vessel and the atmospheric pressure.
Gauge pressures are expressed as "kgf/cm2G", "psig" or"kPa(G)".
Absolute pressure.. .Absolute pressure is the "total" or "true" pressure of a fluid. When the fluid pressure
is greater than the atmospheric pressure, the absolute pressure of the fluid is determined by adding the
atmospheric pressure to the gauge pressure, and when the fluid pressure is less than the atmospheric
pressure, the absolute pressure of the fluid is found by subtracting the gauge pressure from the
atmospheric pressure.
Absolute pressures are expressed as "kgf/cm2abs", "psia" or "KPa (A)"
However, it is normal to omit "G", "g", "abs" or "a" except when it is necessary to discriminate gauge
pressure from absolute
Example 1:
A pressure gauge reads 1.8MPa (18kgf/cm2). What is the absolute pressure in this case?
Solution : Absolute pressure=[1.8+0.1] MPa; (18+1.03) kgf/cm2 =1.9MPa; (19.03kgf/cm2)
Example 2 : A compound gauge on the suction pipe reads 200mmHg. What is the absolute pressure?
Solution : Absolute pressure=760-200=560mmHg
(bar) (C) (m3/kg) (kg/m3) (kJ/kg) (kcal/kg) (kJ/kg) (kcal/kg) (kJ/kg) (kcal/kg) (kJ/kg)
1 99.63 1.694 0.59 417.51 99.72 2675.4 639.02 2257.9 539.3 2.0267
1.1 102.32 1.549 0.645 428.84 102.43 2679.6 640.01 2250.8 537.59 2.0373
1.2 104.81 1.428 0.7 439.36 104.94 2683.4 640.93 2244.1 535.99 2.0476
1.3 107.13 1.325 0.755 449.19 107.29 2687 641.77 2237.8 534.49 2.0576
1.4 109.32 1.236 0.809 458.42 109.49 2690.3 642.56 2231.9 533.07 2.0673
1.5 111.37 1.159 0.863 467.13 111.57 2693.4 643.3 2226.2 531.73 2.0768
1.5 111.37 1.159 0.863 467.13 111.57 2693.4 643.3 2226.2 531.73 2.0768
1.6 113.32 1.091 0.916 475.38 113.54 2696.3 643.99 2220.9 530.45 2.086
1.7 115.17 1.031 0.97 483.22 115.42 2699 644.64 2215.8 529.22 2.095
1.8 116.93 0.977 1.023 490.7 117.2 2701.5 645.25 2210.8 528.05 2.1037
1.9 118.62 0.929 1.076 497.85 118.91 2704 645.83 2206.1 526.92 2.1124
2 120.23 0.885 1.129 504.71 120.55 2706.3 646.39 2201.6 525.84 2.1208
2.2 123.27 0.81 1.235 517.63 123.63 2710.6 647.42 2193 523.78 2.1372
2.4 126.09 0.746 1.34 529.64 126.5 2714.6 648.36 2184.9 521.86 2.1531
2.6 128.73 0.693 1.444 540.88 129.19 2718.2 649.22 2177.3 520.04 2.1685
2.8 131.2 0.646 1.548 551.45 131.71 2721.5 650.03 2170.1 518.32 2.1835
3 133.54 0.606 1.651 561.44 134.1 2724.7 650.77 2163.2 516.68 2.1981
3.5 138.87 0.524 1.908 584.28 139.55 2731.6 652.44 2147.4 512.89 2.2331
4 143.63 0.462 2.163 604.68 144.43 2737.6 653.87 2133 509.45 2.2664
4.5 147.92 0.414 2.417 623.17 148.84 2742.9 655.13 2119.7 506.29 2.2983
5 151.85 0.375 2.669 640.12 152.89 2747.5 656.24 2107.4 503.35 2.3289
5.5 155.47 0.342 2.92 655.81 156.64 2751.7 657.23 2095.9 500.6 2.3585
6 158.84 0.315 3.17 670.43 160.13 2755.5 658.13 2085 498 2.3873
6.5 161.99 0.292 3.419 684.14 163.4 2758.9 658.94 2074.7 495.54 2.4152
7 164.96 0.273 3.667 697.07 166.49 2762 659.69 2064.9 493.2 2.4424
7.5 167.76 0.255 3.915 709.3 169.41 2764.8 660.37 2055.5 490.96 2.469
8 170.42 0.24 4.162 720.94 172.19 2767.5 661 2046.5 488.8 2.4951
8.5 172.94 0.227 4.409 732.03 174.84 2769.9 661.58 2037.9 486.73 2.5206
9 175.36 0.215 4.655 742.64 177.38 2772.1 662.11 2029.5 484.74 2.5456
9.5 177.67 0.204 4.901 752.82 179.81 2774.2 662.61 2021.4 482.8 2.5702
10 179.88 0.194 5.147 762.6 182.14 2776.2 663.07 2013.6 480.93 2.5944
11 184.06 0.177 5.638 781.11 186.57 2779.7 663.91 1998.6 477.35 2.6418
12 187.96 0.163 6.127 798.42 190.7 2782.7 664.64 1984.3 473.94 2.6878
13 191.6 0.151 6.617 814.68 194.58 2785.4 665.29 1970.7 470.7 2.7327
14 195.04 0.141 7.106 830.05 198.26 2787.8 665.85 1957.7 467.6 2.7767
15 198.28 0.132 7.596 844.64 201.74 2789.9 666.35 1945.2 464.61 2.8197
16 201.37 0.124 8.085 858.54 205.06 2791.7 666.79 1933.2 461.74 2.862
17 204.3 0.117 8.575 871.82 208.23 2793.4 667.18 1921.6 458.95 2.9036
18 207.11 0.11 9.065 884.55 211.27 2794.8 667.53 1910.3 456.26 2.9445
19 209.79 0.105 9.556 896.78 214.19 2796.1 667.83 1899.3 453.64 2.9849
20 212.37 0.1 10.047 908.56 217.01 2797.2 668.1 1888.7 451.1 3.0248
21 214.85 0.095 10.539 919.93 219.72 2798.2 668.33 1878.3 448.61 3.0643
22 217.24 0.091 11.032 930.92 222.35 2799 668.54 1868.1 446.19 3.1034
23 219.55 0.087 11.525 941.57 224.89 2799.8 668.71 1858.2 443.82 3.1421
24 221.78 0.083 12.02 951.9 227.36 2800.4 668.86 1848.5 441.5 3.1805
25 223.94 0.08 12.515 961.93 229.75 2800.9 668.99 1839 439.23 3.2187
26 226.03 0.077 13.012 971.69 232.08 2801.4 669.09 1829.7 437.01 3.2567
27 228.06 0.074 13.509 981.19 234.35 2801.7 669.17 1820.5 434.82 3.2944
28 230.04 0.071 14.008 990.46 236.57 2802 669.24 1811.5 432.67 3.332
29 231.96 0.069 14.508 999.5 238.73 2802.2 669.28 1802.7 430.56 3.3695
30 233.84 0.067 15.009 1008.33 240.84 2802.3 669.31 1793.9 428.48 3.4069
(total heat)
The Saturated Steam Table with properties as boiling point, specific volume, density,
specific enthalpy, specific heat and latent heat of vaporization
ST-01-03 A-2
STEAM PIPING
SATURATED STEAM PROPERTY
Abs. pres.
Boiling
point
Specific
volume
(steam)
Density
(steam)
Specific enthalpy
of liquid water (sensible
heat)
Specific enthalpy of
steam
Latent heat of
vaporization
Specific
heat
Example:
A pressure gauge at Steam header indicates 7.0kgf/cm2. What is the steam temperature in this case?
Solution : Absolute pressure= (7.0+1.03) kgf/cm2 = 8.03kgf/cm2
=> Steam temperature is ~ 170 C
Linear coefficient of expansion of various material pipes ; Unit m/m
(source) Mechanical engineering handbook
For PVC pipe, reference value of manufacturer
Carbon Steel Pipe
SUS Pipe
Copper Pipe
Polyvinyl chloride pipe
608010
-6
Copper pipe
16.510
-6
Stainless pipe
16.710
-6
Steel pipe
12.210
-6
Cast iron pipe
10.510
-6
184
0.2
0.4
0.6
0.8
1
134
152
165
175
Saturated
vapor temp
120
Pipe expansion/contraction per meter
Gauge pressure
MPa
0.1
Saturated vapor temperature
96-2
ST-01-04
H-103-E
B-1
STEAM PIPING
EXPANSION AMOUNT
Steel pipe
Stainless steel , copper
PVC
P
i
p
e
e
x
p
a
n
s
i
o
n
/
c
o
n
t
r
a
c
t
i
o
n
p
e
r
m
e
t
e
r
(
m
m
)
Temperature difference t()
The temperature expansion of pipes depends on the start and final temperature of the pipe and the
expansion coefficient of the piping material at the actual temperature. The general expansion formula
can be expressed as:
L = xL x t
where
L = expansion (m, inch)
L = length of pipe (m, inch)
t= temperature difference (C, F)
= Linear coefficient of expansion (m/mC)
) ( ) (
) / (
3 ) (
10 2 . 12
C
t
m
C m mm
EX
mm
O
o
L L =
) ( ) (
) / (
3 ) (
10 7 . 16
C
t
m
C m mm
EX
mm
O
o
L L =
) ( ) (
) / (
3 ) (
10 5 . 16
C
t
m
C m mm
EX
mm
O
o
L L =
TWO METHODS (for TERUMO BCT SITE)
METHOD 1: EXPANSION LOOP
Advantages:
1. Water leak: very low posiblity [Note] 1. All the fittings of expansion loop should be welded
2. Anchor load: small 2. Should be mounted in between fixed points
3. Installation cost: inexpensive 3. Should not be branched from the loop
4. Access hole: not necessary
5. Installation place: roof space, horizontal * Although many designers frequently use EJ,
expansion loop is more effective for hot/cold water
piping which allows smaller expansion capacity.
Disadvantages
1. Need big space for loop installation
METHOD 2: EXPANSION JOINT
Advantages [Note] 1. Guiding bolt must be removed
1. Need small space after installation
2. Mainly accommodate axial
Disdvantages: movement while slightly absorb
1. Water leak: High Posiblity lateral movement
2. Anchor load: Big 3. Should be mounted in the
3. Installation cost: Expensive right direction
4. Access hole: Necessary (must) 4. Pipes should be guided to
5. Installation place: Piping rack accommodate vibration
6. Expansion capacity: max. 50 mm 5. Should not be over-pressurized
7. Guiding: needs multiple guides in water pressure test on site
(standard interval of steel bracing is acceptable)
ST-01-05 B-2
STEAM PIPING
PIPE EXPANSION ABSOBTION
Guide Anchor/Fixing
Guide Anchor/Fixing
Loop
Expansion
METHOD 1: EXPANSION LOOP
Installation of expansion loop
(1) Expansion loop size --- carbon steel piping
Example Pipe diameter 4" with expansion capacity 100mm
W and H of loop should be: W=1.5m and H=3.3m
Test Pipe diameter 50A with expansion capacity 48mm
W and H of loop should be: W=...m and H=..m
ST-01-06 B-2
STEAM PIPING
PIPE EXPANSION ABSOBTION
Expansion capacity e (mm)
P
i
p
e
d
i
a
m
e
t
e
r
(
B
)
METHOD 2: EXPANSION JOINT
EXAMPLE OF VENN JB-14 SERIES
NOTE:
Pipe Expansion <=> Expansion Joint Contraction
ST-01-07 B-2
STEAM PIPING
PIPE EXPANSION ABSOBTION
Expansion
Expansion
Contraction
Contraction
FIXING AND GUIDING METHOD
A. Fixing/guiding interval
(material: SS400)
(1kg=9.8N, 1kg/cm
2
=0.098MPa)
Relation of normal pressure (P kg/cm
2
) and
guiding interval L
2
(carbon steel pipe)
Requirements for 1. able to withstand horizontal load
metallic attachment 2. avoid unnecessary material
3. easy to manufacture (simple structure)
h should be as small as possible
(to reduce bending moment)
102 H-104-A
B-2
STEAM PIPING
PIPE EXPANSION ABSOBTION
Nominal size
3/8
Allowable shear stress
ST-01-08
Allowable stress 58.8MPa (600kg/cm
2
)
26 265
under normal state kN(kg)
1176
1633
1/2
5/8
3/4
7/8
115
160
46
77
2145
2698
1 1/4
1 3/8
1
1 1/8
210
264
339
402
493
558
6789
7691
5033
5697
470
787
2 877 8947
3462
4102
753
1 1/2
1 5/8
Bolt shear stress
1 3/4
1 7/8
665
2
Cantilever shear stress
Normal pressure (kg/cm
2
)
Guiding
interval
(m)
Guided
Guided
(double-bellows)
Anchor
When pipe diameter is D, L
1
should not exceed 4D
(single-bellows)
Anchor Anchor
Fixed Fixed
FIXING AND GUIDING METHOD
B. Fixing/guiding of steam or hot water piping
1. Making use of structural beam
If piping load exceeds 1.96kN (2,000kg), gusset plate
should be installed to reinforce bracket
Bending moment on fixed point includes weight of riser.
should be as short as possible.
ST-01-09
103 H-104-B
B-2
STEAM PIPING
PIPE EXPANSION ABSOBTION
(Material)
Expand
welded
insulation
[Main fixing point]
Angle steel (H800)
20-100A L5x40x40
125-250A L5x50x50
Anchor bolt (p<5kg/cm
2
)
20-100A 12 x 4 pcs
125-250A 15 x 6pcs
(+2pcs for existing building)
Insulation gusset plate
welded
[Main/sub-fixing point]
W=D+200
D --- Pipe nominal size
expand
welded
Reinforcment
beam
metallic
Channel steel
or
[Riser]
l
[Riser]
FIXING AND GUIDING METHOD
2. Making use of slab --- fixing onto slab is not recommended (possibility of fall)
3. Inside tunnel
Piping arrangement is designed along the wall For pipe hanger, flat bar is preferred to round bar,
in order to secure space for maintenance. which should be welded to pipe.
Fixing/guiding method with the help of wall For , strength of anchor bolt should be checked
should be sought. especially for high-temperature steam service.
4. Fixing of bending part
ST-01-10
104 H-104-B
B-2
STEAM PIPING
PIPE EXPANSION ABSOBTION
(Material)
Angle steel (H1,000)
20-100A L5x40x40
125-250A L5x50x50
Anchor bolt (p<5kg/cm
2
)
20-100A 12 x 4 pcs
125-250A 15 x 6pcs
W=D+200
D --- Pipe nominal size
[Main/sub-fixing point]
Insulation
welded
approx 1/5 H
When H>800
welded
welded
welded
welded
water
proof
mortar
Concrete pad
Anchor bolt
hooked up with slab reinforcement
welded welded
welded
C
FIXING AND GUIDING METHOD
5. Inside trench
6. Guiding
[Requirements of metallic guides] a. Friction should be smaller
b. Piping misalignment or movement should be restrained
(Ceiling-mounted piping)
(Riser) (Floor-mounted piping)
* Although pipe itself can be entirely insulated,
installation of pipe shoes is somewhat painstaking.
ST-01-11
105 H-104-B
B-2
STEAM PIPING
PIPE EXPANSION ABSOBTION
Plan view
Plate
Sleeve
Elevation view
Riser clamp
Insulation tube
Pipe hangers and supports
Regular roller support
Hanger
Pipe sleeve
U-bolt or flat bar
pipe strap
Chain Chain
Bracket
Guide
Hanger
Hanger Guide
Fixed
* Guides should be installed every 2-3 hangers
welded
waterproof
(asphalt, pitch,
etc.)
U-bolt to eliminate
vibration
roller support
* prepare drain ditch where necessary
FIXING AND GUIDING METHOD
C. Fixing/guiding of hot/cold water piping
1. Insulated piping
a) insulation may interfere with fixing/guiding
b) condensation may occur through bolt
Although condensation can
be completely prevented,
this requires higher cost.
2. Fastening by welding on site
[Note] Pipe can be tightly attached in the above method, but condensation may
occur with cold water piping. Applicable only for hot water piping.
3. Pipe is insulated at sub-fixing point (where tight fastening is not necessary)
For cooling water piping
1. Expansion loop is preferred if space is available
2. Wood or rigid urethane O-ring should be applied at hanging part of pipe
ST-01-12
106 H-104-C
B-2
STEAM PIPING
PIPE EXPANSION ABSOBTION
Insulation
welded
direction of
Insulation (cypress)
*lauan not acceptable
U-bolt welded
to pipe
Rigid
urethane
O-ring
welded
insulation
welded
welded
W=D+200
(D --- pipe nominal size)
Rigid urethane O-
ring
Insulation (rigid
urethane O-ring)
Insulation (cypress)
Guiding bracket
U-bolt or hanger
(* if fixed, bending moment
works on bracket)
Dew drain pan
(if necessary; EJ should not be
installed in the room which is
susceptible to water leak)
A. Branch piping of horizontal main pipe
B. Use of eccentric reducer
C. Avoiding obstruction
D. Use of globe valve
Globe valve should not be installed in horizontal pipe
which carries large volume of steam condensate.
Condensate is likely to be trapped in the valve.
(Valve may be installed horizontally where volume of
condensate is fewer (e.g.) bypass of pipe end trap)
Steam pipe dia. Drainpipe dia. Return pipe dia. Equalizer dia.
125150 50 125150 50
80100 40 80100 40
5065 32 5065 32
2540A 20A 2540A 20A
ST-01-13
62 F-102-A.B.C.D
B-4
STEAM PIPING
BRANCH PIPING (EXAPMPLES)
Bad
expansion/
contraction
expansion/
contraction
branch (up)
Branch (upward)
Branch (upward)
Branch (downward)
Riser
(down)
Horizontal
main
* Condensate is likely trapped
not exceed 600
* Pipe end trap of
main pipe is omitted.
Steam
Steam
Steam
Steam
Steam condensate
Steam condensate
approx. 400
upward (Not against the
steam flow)
downward
Bushing
Bushing
Steam
Obstruction
Drain plug
or valve (15A)
drainpipe
Steam
Drain plug
or valve (15A)
Obstruction
Return
Steam
condensate and
dirt
Steam
condensate
Steam
condensate
and dirt
Steam
d
Equalizer
POI NT
POI NT
* BRANCH PIPING MOVES DUE TO MAIN PIPING THERMAL EXPANSION/CONTRACTION
Comparison by installation position
a) Single fixed point and no support at the end
1. Friction of guides should be minimized and guides should withstand buckling load of pipe
2. Branch pipe should also accommodate expansion/contraction of pipe
(combined with three elbows, etc.)
3. Force at A-1 is small (friction of guides, etc.)
b) Single-bellows EJ with two fixed points
1. Horizontal load on anchors is larger than c) below
2. Branch pipe should also accommodate expansion/contraction of pipe
(combined with three elbows, etc.)
3. Distance between the two fixed points should be within the allowable expansion capacity of EJ
c) Double-bellows EJ with two fixed points
1. Since thermal expansion/contraction () is smaller than a) and b) above, anchor load is small.
(* where it is necessary to minimize piping stress on construction such as building, etc.)
2. Double-belows EJ is more expensive than other types
3. Expansion capacity is larger than b) above and d) below.
d) Two fixed points and EJ (single-bellows) at the end
1. Horizontal load on anchors is larger than c) above but smaller than b).
2. Branch pipe should also accommodate expansion/contraction of pipe
(combined with three elbows, etc.)
3. EJ is less expensive than b) above, but its expansion capacity may become smaller -should be checked in advance.
ST-01-14
95 H-103-B
B-4
STEAM PIPING
BRANCH PIPING (EXAPMPLES)
expansion/contraction
shrink/stretch
Not fixed
(single-
expansion/contraction expansion/contraction
(double-bellows)
(single-
bellows)
expansion/contraction
expansion/contraction expansion/contraction
expansion/contraction
expansion/contraction
expansion/contractio
expansion/contractio
E. Steam branch piping [Reference]
(the number of elbows combined with)
Low pressure steam Lower than 1.0MPa
Condition Temperature difference 100(100-0=100)
Pipe length 25m
Average expansion coefficient of steel pipe 12x10
-6
mm/mm
ST-01-15
63 F-102-EF
B-4
STEAM PIPING
BRANCH PIPING (EXAPMPLES)
4 elbows
2 elbows 3 elbows
2 elbows
3 elbows
4 elbows
expansion/
contraction
expansion/
contraction
expansion/
contraction
D
i
s
t
a
n
c
e
f
r
o
m
a
n
c
h
o
r
t
o
e
l
b
o
w
Distance from anchor to the point of
branching out
Anchor
Horizontal steam main Expansion joint
Anchor
mm
ST-01-16 B-4
STEAM PIPING
BRANCH PIPING - REMINDER
A. Around boiler
-
-
-
- -
- O
-
74
Heat
source
Load side
Remarks
Hexagonal Square Rounded Round (wrench
(Gauge connectig port)
Rimless Fully rimmed Semi-rimmed Insert
(Gauge shape)
Max.
1,900
Bushing
Socket
(3) Low pressure steam
(4) High pressure steam
(5) Installation
ST-01-38
F-107-C
E
STEAM PIPING
STEAM PRESSURE GAUGE
75
H
o
t
w
a
t
e
r
s
u
p
p
l
y
H
o
t
w
a
t
e
r
s
u
p
p
l
y
H
e
a
t
i
n
g
H
e
a
t
i
n
g
H
e
a
t
i
n
g
H
e
a
t
i
n
g
"
"
A/C Direct heating
Booster heater
Symbol
Pressure gauge ompound gauge
Pressure reducing
valve
Pressure gauge should be installed in the following cases:
When it is necessary to distinguish circuits in
summer/wintertime.
Pressure is reduced in each circuit
Air
K
i
t
c
h
e
n
K
i
t
c
h
e
n