TATA CONSULTING ENGINEERS SECTION: TITLE

TCE.M6-ME-590-416 SHEET i OF iii

DESIGN GUIDE FOR AUXILIARY STEAM HEADER

DESIGN GUIDE

FOR

AUXILIARY STEAM HEADER

FLOPPY NO :
FILE NAME : M6590416.DOC

REV.NO R0 R1 ISSUE

INITIALS SIGN INITIALS SIGN INITIALS SIGN INITIALS SIGN

PPD.BY RS Sd/- VS

CKD.BY BVR Sd/- DP

R1
APP.BY GS Sd/- MLN/RL

DATE 86-06-24 2000-03-31

FORM NO. 020R2

 TATA CONSULTING ENGINEERS SECTION:CONTENTS
TCE.M6-ME-590-416 SHEET ii OF iii
DESIGN GUIDE FOR AUXILIARY STEAM HEADER

CONTENTS
SL.NO. TITLE SH.NO.

1.0 INTRODUCTION 1

2.0 HEADER SIZE 1

3.0 HEADER FABRICATION 1

4.0 HEADER DRAINAGE 2

5.0 ISOLATING VALVES 2

6.0 SPACING BETWEEN BRANCHES 2

7.0 SUPPORT OF HEADER 3

8.0 PIPE REACTIONS 3

FIGURES

FIGURE - 1 - STEAM HEADER 4

FIGURE - 2A - DRAIN POT WITH TRAP STATION 5

FIGURE - 2B - DRAIN POT WITH M.O VALVE 5

FIGURE - 3 - ANCHOR ON CONCRETE PEDESTAL 6

FIGURE - 4 - SLIDING SUPPORTS ON CONCRETE 7

PEDESTALS

FIGURE - 5 - ANCHOR ON STRUCTURAL STEEL 8

FIGURE - 6 - SLIDING SUPPORT ON STRUCTURAL STEEL 8

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DESIGN GUIDE FOR AUXILIARY STEAM HEADER

REVISION STATUS

REV.NO DATE DESCRIPTION

R0 86-06-24 -

R1 2000-03-31 Generally revised

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TCE.M6-ME-590-416 SHEET 1 OF 8
DESIGN GUIDE FOR AUXILIARY STEAM HEADER

1.0 INTRODUCTION

The distribution of auxiliary steam to various consumers should preferably be

through a header (distributor) which is a short length of adequately-sized pipe
and to which the supply sources and consumer points are connected. Branch
connections are provided on top of the header for all incoming and outgoing
pipelines. The header itself is located just above the floor or platform level.
The arrangement of the auxiliary steam header in a typical power plant is
shown in Fig.1. The principal design features of the auxiliary steam header
are discussed in the following paragraphs. Though power plant applications
are discussed, the principles involved are applicable to other types of plants
as well.

2.0 HEADER SIZE

The header should be sized for the maximum flow to be handled by it. In a
power plant, the design flow of the header is either the capacity of the
auxiliary PRDS connected to it or the maximum flow that can be imported into
the unit from another unit or package boiler through the interconnecting line,
whichever is greater. Generally, headers are designed for lower velocities
than pipelines in order to permit future expansion and / or effect trapping of
moisture / condensate entrained in steam.

3.0 HEADER FABRICATION

3.1 The header with its nozzles can be fabricated in one of the following ways :

a) By welding a series of tees with spool pieces, as required, in between

b) By welding stubs of the required sizes to the header in which the

openings have already been made. The joints are secured through
intersection welds.

c) By using “Weldolets” or “Sockolets” depending on the branch size.

3.2 The first method is to have auxiliary steam header using standard wrought
steel tees with spool pieces.

3.3 The second method employs intersection of joints. The openings in the
header weaken it and additional wall thickness has to be provided on the
header by way of reinforcement. The need for additional wall thickness for the
branch lines should also be examined. In short, reinforcement calculations
have to be carried out for the header. Refer BS : 806 / ASME B 31.1 / IBR for
performing reinforcement calculations.

3.4 In the third method, weldolet type fittings are used alongwith openings made
in the header. These provide full strength joints without the need for
additional reinforcement. It is suggested that preference is given to the use of
weldolets as the amount of welding on the header is substantially reduced.
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DESIGN GUIDE FOR AUXILIARY STEAM HEADER

4.0 HEADER DRAINAGE

4.1 The header being at floor level is a receptacle for condensate formed in the
branch lines. A drain pot should be provided on the header near one end with
a size as per guidelines given in Note-1 of Fig-1. The header should be
sloped towards the drain pot. All branch lines should be sloped towards the
header. The condensate collected in the drain pot is drained either through a
trap or though a motor operated valve, actuated by level switch. Refer Figs.
2A and 2B. The scheme depends on system requirements, operating
pressure and temperature and the quantity of drain to be handled. Traps are
adequate to handle small drain quantities at relatively low pressure and
temperature.

4.2 Motor operated valve actuated with level switch is recommended when the
operating temperature is greater than 400oC or at places where spray water is
introduced into steam piping (e.g. downstream of desuperheater, downstream
of HP Bypass valves).

5.0 ISOLATING VALVES

Isolating valves on branch lines should be located close to the header.

The centre line elevations of the valves should be uniform and should be
1300–1500 mm above the floor. Valves may be staggered to reduce the
centre distances between branch lines. This arrangement presents a neat
appearance renders the operation of valves convenient and ensures quick
and ready identification of the service of the valves. This arrangement implies
that the length of the stubs on the header, upto the valves, may not be
uniform for all branch lines due to differences in end-to-end lengths of valves.
This is however of little consequence.

6.0 SPACING BETWEEN BRANCHES

The spacing between the branch pipes on the header is governed by the
following two requirements.

a) The clear spacing between two branches should be equal to or greater

than the sum of the outside diameter of the two branch pipes in order
to avoid the influence of one branch on the other and thus minimise
reinforcement requirements. This will not be applicable if weldolets
are used.

b) The hand wheels of the isolating valves on adjacent branch lines

should have adequate clearance in between for ease of operation.
The minimum clearance between the outer edges of the valves should
not be less than 150MM.

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DESIGN GUIDE FOR AUXILIARY STEAM HEADER

7.0 SUPPORT OF HEADER

The header should be supported from the floor through bottom pipe supports.
As the steam piping is hot and calls for thermal analysis, the header at one of
the support points should be anchored so as to split the piping connected in
to individual systems for purpose of stress analysis and to minimise the effect
of one branch on the other. Individual systems stress analysis shall be
carried out with header anchor as the anchor. Figures 3 to 6 indicate typical
arrangement for support of anchor and restraints.

8.0 PIPE REACTIONS

As each pipeline connected to the header is being stress analysed

individually, the combined effect of all the pipe reactions at the various take-
off points should be studied and the header stress computed. Similarly, the
anchor and restraints on the header should be designed for the combined
effect of pipe reactions. Here it should be borne in mind that it is not
necessary for all the pipe lines to be hot or cold simultaneously. While
computing the combined reactions, the worst possible combination of the
individual reactions should be considered. The effect due to the reaction
forces of safety relief valves that are mounted on the steam header also need
to be considered while designing the anchors & restraints. Safety valves
should preferably be located near one of the supports of the header.

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DESIGN GUIDE FOR AUXILIARY STEAM HEADER

BETWEEN UNIT HEADERS

INTER CONNECTING LINE
STEAM TO BOILER FUEL

STEAM TO DEAERATOR

STEAM TO EJECTORS
OIL SYSTEM & SCAPH

SPARE CONNECTION

STEAM TO TURBINE
GLAND SEALS
STEAM FROM
AUX. PRDS.

SPARE
TI SAFETY PI
RELIEF VALVE
1300 TO 1500 mm

STEAM HEADER

SLOPE
FLOOR LEVEL

PIPE SUPPORT DRAIN POT

PIPE ANCHOR
WELD CAP(TYP) SEE FIG-4 SEE FIG-2A & 2B
SEE FIG-3 & 5
FOR DETAILS FOR DETAILS
FOR DETAILS

ELEVATION

TI PI

.
IN
M )
0 P
15 TY
(
PLAN

FIGURE.-1

STEAM HEADER

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DESIGN GUIDE FOR AUXILIARY STEAM HEADER

SLOPE C OF HEADER
L

DRAIN POT TRAP STATION

(REF. NOTE-1)

NB 25
T TO FLASH TANK OR WASTE
AS SHOWN IN FLOW DIAGRAM

DRAIN PLUG
(THREADED / WELDED
HALF COUPLING WITH PLUG)

FIGURE-2A
DRAIN POT WITH TRAP STATION

SLOPE C OF HEADER
L

LEGEND
HHLVL
HHLVL HIGH HIGH LEVEL PROBE TYPE
HLVL HIGH LEVEL LEVEL SWITCH
HLVL

M
DRAIN POT
(REF. NOTE-1) NB50
TO FLASH
TANK
(REF. NOTE-2)
DRAIN PLUG
(THREADED / WELDED
HALF COUPLING WITH PLUG)

FIGURE-2B
DRAIN POT WITH M.O VALVE
NOTES:
1. DRAIN POT SIZE SHALL BE AS FOLLOWS
HEADER < 150 mm SAME AS HEADER SIZE
HEADER > 200 mm HALF THE HEADER SIZE
OR 150 mm WHICH EVER IS GREATER.
2. WITH HIGH HIGH LEVEL THE MOTOR OPERATED VALVE WILL OPEN AND
CLOSE AT HIGH LEVEL

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DESIGN GUIDE FOR AUXILIARY STEAM HEADER

DO NOT DRILL HOLE

THICKNESS +
INSULATION

25mm(TYP)
OR 100 mm

STUB
D
A A
(MIN)

2 mm PLATE 10THK.
VENT HOLE
PF
LEGEND
CC
25 GROUT(MIN.)
PF : PIPE FABRICATOR
CC : CIVIL CONTRACTOR
POCKET SIZE
50 S.Q. x 300 LONG
100 FOR b < 300
125 FOR b = 301 TO 400
STUB SIZE DIM. IN mm.
ELEVATION
NB OD(D) a b
b
50 60.3 75 120
a
65 73.0 90 140

80 88.9 110 160

b

100 114.3 140 190

150 168.3 190 240

200 219.1 240 300

250 273 300 350

SECTION A-A
300 323.9 340 400
FIGURE-3
ANCHOR ON CONCRETE PEDESTAL

ERECTION NOTES:
1. THE GROUTING SHOULD BE DONE AFTER SETTING THE PIPE LINE FOR SLOPE
2. HEIGHT OF FOUNDATION SHOULD BE CALCULATED CONSIDERING THE ACTUAL PIPE
ELEVATION AFTER SLOPE AT THE POINT OF SUPPORT
3. PIPE STUB IS NORMALLY ONE OR TWO SIZES SMALLER THAN HEADER SIZE
4. PIPE STUB WALL THICKNESS SHOULD BE CHECKED FOR WORST POSSIBLE COMBINED
PIPE REACTIONS AT ANCHOR. THE REACTIONS FORCES MUST BE INDICATED ON THE
PIPING DRAWING TO ENABLE THE PIPING FABRICATOR TO DESIGN WELD JOINTS.

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TCE.M6-ME-590-416 SHEET 7 OF 8
DESIGN GUIDE FOR AUXILIARY STEAM HEADER

DO NOT DRILL HOLE

THICKNESS +
INSULATION

25mm(TYP)
OR 100 mm

A D
2 mm STUB A
(MIN)

PLATE 10THK.
VENT HOLE

PF

25 GROUT(MIN.)
CC
2 mm
(TYP)

POCKET SIZE
50 S.Q. x 300 LONG
100 FOR b < 300
125 FOR b = 301 TO 400

ELEVATION
PIPE MVT.

b = a + PIPE MOVEMENT IN
THE DIRECTION + 100mm.
a c = a + 200mm.
d = b + 100mm
a = SAME AS IN FIG. 3
b
d

c & d COULD BE MADE EQUAL

IF THERE IS NOT MUCH
DIFFERENCE.

LEGEND
100 FOR b < 300 PF : PIPE FABRICATOR
125 FOR b > 301 TO 400 CC : CIVIL CONTRACTOR
c

SECTION A-A
FIGURE-4
SLIDING SUPPORTS ON CONCRETE PEDASTALS

ERECTION NOTES:
SAME AS NOTES 1 & 3 OF FIGURE - 3

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