Block 10 Steam Distribution Pipes and Pipe Sizing Module 10.

Module 10.2
Pipes and Pipe Sizing

The Steam and Condensate Loop 10.2.1

Block 10 Steam Distribution Pipes and Pipe Sizing Module 10.2

Pipes and Pipe Sizing

Standards and wall thickness
There are a number of piping standards in existence around the world, but arguably the most
global are those derived by the American Petroleum Institute (API), where pipes are categorised
in schedule numbers.
These schedule numbers bear a relation to the pressure rating of the piping. There are eleven
Schedules ranging from the lowest at 5 through 10, 20, 30, 40, 60, 80, 100, 120, 140 to schedule
No. 160. For nominal size piping 150 mm and smaller, Schedule 40 (sometimes called ‘standard
weight’) is the lightest that would be specified for steam applications.
Regardless of schedule number, pipes of a particular size all have the same outside diameter (not
withstanding manufacturing tolerances). As the schedule number increases, the wall thickness
increases, and the actual bore is reduced. For example:
o A 100 mm Schedule 40 pipe has an outside diameter of 114.30 mm, a wall thickness of 6.02
mm, giving a bore of 102.26 mm.
o A 100 mm Schedule 80 pipe has an outside diameter of 114.30 mm, a wall thickness of 8.56
mm, giving a bore of 97.18 mm.
Only Schedules 40 and 80 cover the full range from 15 mm up to 600 mm nominal sizes and are
the most commonly used schedule for steam pipe installations.
This Module considers Schedule 40 pipework as covered in BS 1600.
Tables of schedule numbers can be obtained from BS 1600 which are used as a reference for the
nominal pipe size and wall thickness in millimetres. Table 10.2.1 compares the actual bore sizes
of different sized pipes, for different schedule numbers.
In mainland Europe, pipe is manufactured to DIN standards, and DIN 2448 pipe is included in
Table 10.2.1.
Table 10.2.1 Comparison of pipe standards and actual bore diameters.
Nominal size pipe (mm) 15 20 25 32 40 50 65 80 100 150
Schedule 40 15.8 21.0 26.6 35.1 40.9 52.5 62.7 77.9 102.3 154.1
Schedule 80 13.8 18.9 24.3 32.5 38.1 49.2 59.0 73.7 97.2 146.4
Bore (mm)
Schedule 160 11.7 15.6 20.7 29.5 34.0 42.8 53.9 66.6 87.3 131.8
DIN 2448 17.3 22.3 28.5 37.2 43.1 60.3 70.3 82.5 107.1 159.3

In the United Kingdom, piping to BS 1387, (steel tubes and tubulars suitable for screwing to
BS 21 threads) is also used in applications where the pipe is screwed rather than flanged.
They are commonly referred to as ‘Blue Band’ and ‘Red Band’; this being due to their banded
identification marks. The different colours refer to particular grades of pipe:
o Red Band, being heavy grade, is commonly used for steam pipe applications.
o Blue Band, being medium grade, is commonly used for air distribution systems, although it is
sometimes used for low-pressure steam systems.
The coloured bands are 50 mm wide, and their positions on the pipe denote its length. Pipes less
than 4 metres in length only have a coloured band at one end, while pipes of 4 to 7 metres in
length have a coloured band at either end.

Fig. 10.2.1 Red band, branded pipe, - heavy grade, Fig. 10.2.2 Blue band, branded pipe, - heavy grade,
up to 4 metres in length between 4-7 metres in length

10.2.2 The Steam and Condensate Loop

Block 10 Steam Distribution Pipes and Pipe Sizing Module 10.2

Pipe material
Pipes for steam systems are commonly manufactured from carbon steel to ANSI B 16.9 A106.
The same material may be used for condensate lines, although copper tubing is preferred in
some industries.
For high temperature superheated steam mains, additional alloying elements, such as chromium
and molybdenum, are included to improve tensile strength and creep resistance at high
temperatures.
Typically, pipes are supplied in 6 metre lengths.

Pipeline sizing
The objective of the steam distribution system is to supply steam at the correct pressure to the
point of use. It follows, therefore, that pressure drop through the distribution system is an important
feature.
Bernoulli’s Theorem (Daniel Bernoulli 1700 - 1782) is discussed in Block 4 - Flowmetering.
D’Arcy (D’Arcy Thompson 1860 - 1948) added that for fluid flow to occur, there must be more
energy at Point 1 than Point 2 (see Figure 10.2.3). The difference in energy is used to overcome
frictional resistance between the pipe and the flowing fluid.

hf
h1
h2

Pipe diameter (D) Flow velocity (u)

Length (L)
Point 1 Point 2

Fig. 10.2.3 Friction in pipes

This is illustrated by the D’Arcy equation (Equation 10.2.1):

K = I/Xò Equation 10.2.1

I
J'

Where:
hf = Head loss to friction (m)
f = Friction factor (dimensionless)
L = Length (m)
u = Flow velocity (m /s)
g = Gravitational constant (9.81 m /s²)
D = Pipe diameter (m)
It is useful to remember that:
o Head loss to friction (hf) is proportional to the velocity squared (u²).
o The friction factor (f) is an experimental coefficient which is affected by factors including:
- The Reynolds Number (which is affected by velocity).
- The reciprocal of velocity².
Because the values for ‘f’ are quite complex, they are usually obtained from charts.

The Steam and Condensate Loop 10.2.3

Block 10 Steam Distribution Pipes and Pipe Sizing Module 10.2

Example 10.2.1 - Water pipe

Determine the difference in pressure between two points 1 km apart in a 150 mm bore
horizontal pipework system. The water flowrate is 45 m³ / h at 15°C and the friction factor
for this pipe is taken as 0.005
9ROXPHIORZUDWH ( Pó V )
9HORFLW\ ( P V ) &URVVVHFWLRQDODUHD ( Pò )

9HORFLW\ VPó K[

K[›[ò
9HORFLW\ P V

K = I/Xò Equation 10.2.1

I
J'

[[P[ò
K
[[
I

KI P ≈ EDU

In practice whether for water pipes or steam pipes, a balance is drawn between pipe size and
pressure loss.
Oversized pipework means:
o Pipes, valves, fittings, etc. will be more expensive than necessary.
o Higher installation costs will be incurred, including support work, insulation, etc.
o For steam pipes a greater volume of condensate will be formed due to the greater heat loss. This,
in turn, means that either:
- More steam trapping is required, or
- Wet steam is delivered to the point of use.
In a particular example:
o The cost of installing 80 mm steam pipework was found to be 44% higher than the cost of 50
mm pipework, which would have had adequate capacity.
o The heat lost by the insulated pipework was some 21% higher from the 80 mm pipeline than
it would have been from the 50 mm pipework. Any non-insulated parts of the 80 mm pipe
would lose 50% more heat than the 50 mm pipe, due to the extra heat transfer surface area.
Undersized pipework means:
o A lower pressure may only be available at the point of use. This may hinder equipment
performance due to only lower pressure steam being available.
o There is a risk of steam starvation.
o There is a greater risk of erosion, waterhammer and noise due to the inherent increase in
steam velocity.
As previously mentioned, the friction factor (f) can be difficult to determine, and the calculation
itself is time consuming especially for turbulent steam flow. As a result, there are numerous graphs,
tables and slide rules available for relating steam pipe sizes to flowrates and pressure drops.
One pressure drop sizing method, which has stood the test of time, is the ‘pressure factor’ method.
A table of pressure factor values is used in Equation 10.2.2 to determine the pressure drop for a
particular installation.

) = 3 3 Equation 10.2.2

/

Where:
F = Pressure factor
P1 = Factor at inlet pressure
P2 = Factor at a distance of L metres
L = Equivalent length of pipe (m)

10.2.4 The Steam and Condensate Loop

Block 10 Steam Distribution Pipes and Pipe Sizing Module 10.2

Example 10.2.2
Consider the system shown in Figure 10.2.4, and determine the pipe size required from the
boiler to the unit heater branch line. Unit heater steam load = 270 kg /h.
P1 = 7 bar g P2 = 6.6 bar g
L = 150 m

150 m (original pipe length)

+ 10 % (allowance for pipe fittings)
= 165 m (revised pipe length)

Boiler at Unit heater

Revised load to supply the heater battery is
7.0 bar g at 6.6 bar g
270 kg/h + 5.8% = 286 kg/h
286 kg/h 270 kg/h
Fig. 10.2.4 System used to illustrate Example 10.2.2

Although the unit heater only requires 270 kg /h, the boiler has to supply more than this due to
heat losses from the pipe.
The allowance for pipe fittings
The length of travel from the boiler to the unit heater is known, but an allowance must be
included for the additional frictional resistance of the fittings. This is generally expressed in terms
of ‘equivalent pipe length’. If the size of the pipe is known, the resistance of the fittings can be
calculated. As the pipe size is not yet known in this example, an addition to the equivalent length
can be used based on experience.
o If the pipe is less than 50 metres long, add an allowance for fittings of 5%.
o If the pipe is over 100 metres long and is a fairly straight run with few fittings, an allowance for
fittings of 10% would be made.
o A similar pipe length, but with more fittings, would increase the allowance towards 20%.
In this instance, revised length = 150 m + 10% = 165 m
The allowance for the heat losses from the pipe
The unit heater requires 270 kg /h of steam; therefore the pipe must carry this quantity plus the
quantity of steam condensed by heat losses from the main. As the size of the main is yet to be
determined, the true calculations cannot be made, but, assuming that the main is insulated, it
may be reasonable to add 3.5% of the steam load per 100 m of the revised length as heat losses.

In this instance, the additional allowance =

[ 
Revised boiler load = 270 kg /h + 5.8% = 286 kg /h
From Table 10.2.2 (an extract from the complete pressure factor table, Table 10.2.5, which can
be found in the Appendix at the end of this Module) ‘F‘ can be determined by finding the
pressure factors P1 and P2, and substituting them into Equation 10.2.2.
Table 10.2.2 Extract from pressure factor table (Table 10.2.5)
Pressure bar g Pressure factor (F)
6.5 49.76
6.6 51.05
6.7 52.36

6.9 55.02
7.0 56.38
7.1 57.75

The Steam and Condensate Loop 10.2.5

Block 10 Steam Distribution Pipes and Pipe Sizing Module 10.2

From the pressure factor table:

P1 (7.0 bar g) = 56.38
P2 (6.6 bar g) = 51.05
Substituting these pressure factors (P1 and P2 ) into Equation 10.2.2 will determine the value for ‘F’:

) 3 3 Equation 10.2.2

/

) 
P
) 
Following down the left-hand column of the pipeline capacity and pressure drop factors table
(Table 10.2.6 - Extract shown in Table 10.2.3); the nearest two readings around the requirement
of 0.032 are 0.030 and 0.040. The next lower factor is always selected; in this case, 0.030.
Table 10.2.3 Extract from pipeline capacity and pressure factor table (Table 10.2.6)
Pipe size (DN)
Factor 15 20 25 32 40 50 65 80 100 150 200
(F)
Capacity (kg /h)
0.025 10.99 33.48 70.73 127.3 209.8 459.7 834.6 1 367 2 970 8 817 19 332
0.030 12.00 36.78 77.23 137.9 229.9 501.1 919.4 1 480 3 264 9 792 20 917
0.040 14.46 44.16 93.17 169.2 279.5 600.7 1 093 1 790 3 923 11 622 25 254

Although values can be interpolated, the table does not conform exactly to a straight-line graph,
so interpolation cannot be absolutely correct. Also, it is bad practice to size any pipe up to the
limit of its capacity, and it is important to have some leeway to allow for the inevitable future
changes in design.
From factor 0.030, by following the row of figures to the right it will be seen that:
o A 40 mm pipe will carry 229.9 kg /h.
o A 50 mm pipe will carry 501.1 kg /h.
Since the application requires 286 kg /h, the 50 mm pipe would be selected.
Having sized the pipe using the pressure drop method, the velocity can be checked if required.
9ROXPHIORZ ( Pó V )
6WHDPYHORFLW\ &URVVVHFWLRQDODUHDRISLSH P V
( Pò ) 

( NJ K ) [Y ( Pó NJ ) [
6WHDPYHORFLW\ 6WHDPIORZUDWH
 V K[π['ò ( Pò )
J
P V
Where:
6WHDPIORZUDWH  NJ K UHYLVHGORDG
6SHFLILFYROXPHY J   P ó NJ $WEDUJ
3LSHGLDPHWHU' PFDOFXODWHGDERYH
 NJ K [ P ó NJ[
6WHDPYHORFLW\ P V
 V K[π [ò  ( P ò )
6WHDPYHORFLW\ P V

Viewed in isolation, this velocity may seem low in comparison with maximum permitted
velocities. However, this steam main has been sized to limit pressure drop, and the next smaller
pipe size would have given a velocity of over 47 m/s, and a final pressure less than the
requirement of 6.6 bar g.

10.2.6 The Steam and Condensate Loop

Block 10 Steam Distribution Pipes and Pipe Sizing Module 10.2

As can be seen, this procedure is fairly complex and can be simplified by using the nomogram
shown in Table 10.2.7 (in the Appendix at the end of this Module). The method of use is explained
in Example 10.2.3.
Example 10.2.3
Using the data from Example 10.2.2, determine the pressure drop using the nomogram
shown in Figure 10.2.5 (same as Table 10.2.7).
Inlet pressure = 7 bar g
Steam flowrate = 286 kg /h
( 3 3 )
0D[LPXPSUHVVXUHGURSSHUP [
/
(  )
0D[LPXPSUHVVXUHGURSSHUP [

0D[LPXPSUHVVXUHGURSSHUP EDU
Method:
o Select the point on the saturated steam line at 7 bar g, and mark Point A.
o From point A, draw a horizontal line to the steam flowrate of 286 kg /h, and mark Point B.
o From point B, draw a vertical line towards the top of the nomogram (Point C).
o Draw a horizontal line from 0.24 bar /100 m on the pressure loss scale (Line DE).
o The point at which lines DE and BC cross will indicate the pipe size required. In this case, a
40 mm pipe is too small, and a 50 mm pipe would be used.
20
C
10

5
10

15

3
20

2
25
Pressure loss bar / 100 m

30
40

1
50
60
70
80

0.5
100
125

0.3
150

D E
200

0.2
mm
250
300

0.1
ete
400
500

iam
pip 600

0.05
ed

0.03
0.02
ide
Ins

0.01
Steam pressure bar g

um
50% vacu
10

0 bar g
20
30

0.5
50
100

1
200

2
300
500

3
0
100

5
3 0 00
00

7
20

00

A 10
000
50

15
30 000
000

Saturation
10

g/h

20
000
20

temperature
000

30
ek
50

curve
flow 00
rat
100

B
am 200 0

50
70
100
Ste

100 200 300 400 500

Steam temperature °C

Fig. 10.2.5 Steam pipeline sizing chart - Pressure drop

The Steam and Condensate Loop 10.2.7

Block 10 Steam Distribution Pipes and Pipe Sizing Module 10.2

Sizing pipes on velocity

From the knowledge gained at the beginning of this Module, and particularly the notes regarding
the D’Arcy equation (Equation 10.2.1), it is acknowledged that velocity is an important factor in
sizing pipes. It follows then, that if a reasonable velocity could be used for a particular fluid
flowing through pipes, then velocity could be used as a practical sizing factor. As a general rule, a
velocity of 25 to 40 m /s is used when saturated steam is the medium.
40 m /s should be considered an extreme limit, as above this, noise and erosion will take place
particularly if the steam is wet.
Even these velocities can be high in terms of their effect on pressure drop. In longer supply lines,
it is often necessary to restrict velocities to 15 m /s to avoid high pressure drops. It is recommended
that pipelines over 50 m long are always checked for pressure drop, no matter what the velocity.
By using Table 10.2.4 as a guide, it is possible to select pipe sizes from known data; steam
pressure, velocity and flowrate.
Table 10.2.4 Saturated steam pipeline capacities in kg /h for different velocities (Schedule 40 pipe)
Pipe size (nominal)
15 20 25 32 40 50 65 80 100 125 150
Pressure Velocity
Actual inside pipe diameter Schedule 40
bar g m/s
15.80 20.93 26.64 35.04 40.90 52.50 62.70 77.92 102.26 128.20 154.05
Pipeline capacity kg /h
15 9 15 25 43 58 95 136 210 362 569 822
0.4 25 14 25 41 71 97 159 227 350 603 948 1 369
40 23 40 66 113 154 254 363 561 965 1 517 2 191
15 10 18 29 51 69 114 163 251 433 681 983
0.7 25 17 30 49 85 115 190 271 419 722 1 135 1 638
40 28 48 78 136 185 304 434 671 1 155 1 815 2 621
15 12 21 34 59 81 133 189 292 503 791 1 142
1 25 20 35 57 99 134 221 315 487 839 1 319 1 904
40 32 56 91 158 215 354 505 779 1342 2 110 3 046
15 18 31 50 86 118 194 277 427 735 1 156 1 669
2 25 29 51 83 144 196 323 461 712 1 226 1 927 2 782
40 47 82 133 230 314 517 737 1 139 1 961 3 083 4 451
15 23 40 65 113 154 254 362 559 962 1 512 2 183
3 25 38 67 109 188 256 423 603 931 1 603 2 520 3 639
40 61 107 174 301 410 676 964 1 490 2 565 4 032 5 822
15 28 50 80 139 190 313 446 689 1 186 1 864 2 691
4 25 47 83 134 232 316 521 743 1 148 1 976 3 106 4 485
40 75 132 215 371 506 833 1 189 1 836 3 162 4 970 7 176
15 34 59 96 165 225 371 529 817 1 408 2 213 3 195
5 25 56 98 159 276 375 619 882 1 362 2 347 3 688 5 325
40 90 157 255 441 601 990 1 411 2 180 3 755 5 901 8 521
15 39 68 111 191 261 430 613 947 1 631 2 563 3 700
6 25 65 114 184 319 435 716 1 022 1 578 2 718 4 271 6 167
40 104 182 295 511 696 1 146 1 635 2 525 4 348 6 834 9 867
15 44 77 125 217 296 487 695 1 073 1 848 2 904 4 194
7 25 74 129 209 362 493 812 1 158 1 788 3 080 4 841 6 989
40 118 206 334 579 788 1 299 1 853 2 861 4 928 7 745 11 183
15 49 86 140 242 330 544 775 1 198 2 063 3 242 4 681
8 25 82 144 233 404 550 906 1 292 1 996 3 438 5 403 7 802
40 131 230 373 646 880 1 450 2 068 3 194 5 501 8 645 12 484
15 60 105 170 294 401 660 942 1 455 2 506 3 938 5 686
10 25 100 175 283 490 668 1 101 1 570 2 425 4 176 6 563 9 477
40 160 280 453 785 1 069 1 761 2 512 3 880 6 682 10 502 15 164
15 80 141 228 394 537 886 1 263 1 951 3 360 5 281 7 625
14 25 134 235 380 657 896 1 476 2 105 3 251 5 600 8 801 12 708
40 214 375 608 1 052 1 433 2 362 3 368 5 202 8 960 14 082 20 333

10.2.8 The Steam and Condensate Loop

Block 10 Steam Distribution Pipes and Pipe Sizing Module 10.2

Alternatively the pipe size can be calculated arithmetically. The following information is required,
and the procedure used for the calculation is outlined below.
Information required to calculate the required pipe size:
u = Flow velocity (m /s)
vg = Specific volume (m³ /kg)
ms = Mass flowrate (kg /s)
V = Volumetric flowrate (m³ /s) = ms x vg
From this information, the cross sectional area (A) of the pipe can be calculated:
9ROXPHIORZUDWH (  )
&URVVVHFWLRQDODUHD$
)ORZYHORFLW\ ( X )
π ['ò 
LH
 X
Rearranging the formula to give the diameter of the pipe (D) in metres:
[
' =
π [X
[
'=
π [X
Example 10.2.4
A process requires 5 000 kg /h of dry saturated steam at 7 bar g. For the flow velocity not to
exceed 25 m /s, determine the pipe size.
Where:
)ORZYHORFLW\X  P V
6SHFLILFYROXPHDWEDUJY J   Pó NJ
0DVVIORZUDWH   NJ KRU NJ V
9ROXPHWULFIORZUDWH [Y J

9ROXPHWULFIORZUDWH  NJ V [Pó NJ

9ROXPHWULFIORZUDWH Pó V

Therefore, using:
9ROXPHWULFIORZUDWH (  )
&URVVVHFWLRQDODUHD$
)ORZYHORFLW\ ( X )
π['ò 
 X
[
'ò π[X
[
' π[X
[
3LSHGLDPHWHU'
π[
3LSHGLDPHWHU' PRUPP
Since the steam velocity must not exceed 25 m /s, the pipe size must be at least 130 mm; the
nearest commercially available size, 150 mm, would be selected.
Again, a nomogram has been created to simplify this process, see Figure 10.2.6.

The Steam and Condensate Loop 10.2.9

Block 10 Steam Distribution Pipes and Pipe Sizing Module 10.2

Example 10.2.5
Using the information from Example 10.2.4, use Figure 10.2.6 to determine the minimum
acceptable pipe size
Inlet pressure = 7 bar g
Steam flowrate = 5 000 kg /h
Maximum velocity = 25 m /s
Method:
o Draw a horizontal line from the saturation temperature line at 7 bar g (Point A) on the pressure

scale to the steam mass flowrate of 5 000 kg /h (Point B).

o From point B, draw a vertical line to the steam velocity of 25 m /s (Point C). From point C, draw
a horizontal line across the pipe diameter scale (Point D).
o A pipe with a bore of 130 mm is required; the nearest commercially available size, 150 mm,
would be selected.
600
500
400

300

/s
m 200
city
lo 150
ve 5
m D
ea C
St

Pipe diameter mm
10
100
20
30
50
0
10 50
1 50
40

30

20

10 Steam pressure bar g

/h
kg
ate 10 50% va
cuum
r
w 20 0
flo 3
m 0 bar g
ea 50
St 0
10 0.5
0 1
20 00 2
3 0
50 3
00 5
10
00 A 7
2 0 000 B 10
3 00 Saturation
50 0 temperature
15
00 20
10 0 curve
00 0 30
20 0 00 0
3 00 50
50 00 70
00
10 00 100
00
20

100 200 300 400 500

Steam temperature °C
Fig. 10.2.6 Steam pipeline sizing chart - Velocity

10.2.10 The Steam and Condensate Loop

Block 10 Steam Distribution Pipes and Pipe Sizing Module 10.2

Sizing pipes for superheated steam duty

Superheated steam can be considered as a dry gas and therefore carries no moisture.
Consequently there is no chance of pipe erosion due to suspended water droplets, and steam
velocities can be as high as 50 to 70 m/s if the pressure drop permits this. The nomograms in
Figures 10.2.5 and 10.2.6 can also be used for superheated steam applications.
Example 10.2.6
Utilising the waste heat from a process, a boiler /superheater generates 30 t /h of superheated
steam at 50 bar g and 450°C for export to a neighbouring power station. If the velocity is not
to exceed 50 m /s, determine:
1. The pipe size based on velocity (use Figure 10.2.8).
2. The pressure drop if the pipe length, including allowances, is 200 m (use Figure 10.2.7).
Part 1
o Using Figure 10.2.8, draw a vertical line from 450°C on the temperature axis until it intersects

the 50 bar line (Point A).

o From point A, project a horizontal line to the left until it intersects the steam ‘mass flowrate’
scale of 30 000 kg /h (30 t /h) (Point B).
o From point B, project a line vertically upwards until it intersects 50 m /s on the ‘steam velocity’
scale (Point C).
o From Point C, project a horizontal line to the right until it intersects the ‘inside pipe diameter’
scale.
The ‘inside pipe diameter’ scale recommends a pipe with an inside diameter of about 120 mm.
From Table 10.2.1 and assuming that the pipe will be Schedule 80 pipe, the nearest size would
be 150 mm, which has a bore of 146.4 mm.
Part 2
o Using Figure 10.2.7, draw a vertical line from 450°C on the temperature axis until it intersects
the 50 bar line (Point A).
o From point A, project a horizontal line to the right until it intersects the ‘steam mass flowrate’
scale of 30 000 kg /h (30 t /h) (Point B).
o From point B, project a line vertically upwards until it intersects the ‘inside pipe diameter’ scale
of (approximately) 146 mm (Point C).
o From Point C, project a horizontal line to the left until it intersects the ‘pressure loss bar/100 m’
scale (Point D).
The ‘pressure loss bar /100 m’ scale reads about 0.9 bar /100 m. The pipe length in the example
is 200 m, so the pressure drop is:
P
3UHVVXUHGURS [EDU EDU
P
This pressure drop must be acceptable at the process plant.

The Steam and Condensate Loop 10.2.11

Block 10 Steam Distribution Pipes and Pipe Sizing Module 10.2

Using formulae to establish steam flowrate on pressure drop

Empirical formulae exist for those who prefer to use them. Two formulae are shown below that
have been tried and tested over many years, and which appear to give results close to the pressure
factor method. The advantage of using these formulae is that they can be programmed into a
scientific calculator, or a spreadsheet, and consequently used without the need to look up tables
and charts. The second formula requires the specific volume of steam to be known, which means
it is necessary to look up this value from a steam table.

Pressure drop formula 1

( 3 )   ( 3 )  
/ '
Where:
P1 = Upstream pressure (bar a)
P2 = Downstream pressure (bar a)
L = Length of pipe (m)
m = Mass flowrate (kg /h)
D = Pipe diameter (mm)

Pressure drop formula 2

∆3
/YJ  ò
'
Where:
DP = Pressure drop (bar)
L = Length of pipe (m)
vg = Specific volume of steam (m³ /kg)
m = Mass flowrate (kg /h)
D = Pipe diameter (mm)

Summary
o The selection of piping material and the wall thickness required for a particular installation is
stipulated in standards such as BS 806 (1993) and ASME 31.1.
o Selecting the appropriate pipe size (nominal bore) for a particular application is based on
accurately identifying pressure and flowrate. The pipe size may be selected on the basis of:
- Velocity (usually pipes less than 50 m in length).
- Pressure drop (as a general rule, the pressure drop should not normally exceed 0.1 bar /50 m.

10.2.12 The Steam and Condensate Loop

Block 10 Steam Distribution Pipes and Pipe Sizing Module 10.2

Appendix
Table 10.2.5 Pressure drop factor (F) table
Pressure Pressure Pressure Pressure Pressure Pressure
bar a factor (F) bar g factor (F) bar g factor (F)
0.05 0.0301 2.05 8.748 7.60 64.84
0.10 0.0115 2.10 9.026 7.70 66.31
0.15 0.0253 2.15 9.309 7.80 67.79
0.20 0.0442 2.20 9.597 7.90 69.29
0.25 0.0681 2.25 9.888 8.00 70.80
0.30 0.0970 2.30 10.18 8.10 72.33
0.35 0.1308 2.35 10.48 8.20 73.88
0.40 0.1694 2.40 10.79 8.30 75.44
0.45 0.2128 2.45 11.40 8.40 77.02
0.50 0.2610 2.50 11.41 8.50 78.61
0.55 0.3140 2.55 11.72 8.60 80.22
0.60 0.3716 2.60 12.05 8.70 81.84
0.65 0.4340 2.65 12.37 8.80 83.49
0.70 0.5010 2.70 12.70 8.90 85.14
0.75 0.5727 2.75 13.03 9.00 86.81
0.80 0.6489 2.80 13.37 9.10 88.50
0.85 0.7298 2.85 13.71 9.20 90.20
0.90 0.8153 2.90 14.06 9.30 91.92
0.95 0.9053 2.95 14.41 9.40 93.66
1.013 1.0250 3.00 14.76 9.50 95.41
3.10 15.48 9.60 97.18
3.20 16.22 9.70 98.96
Pressure Pressure 3.30 16.98 9.80 100.75
bar g factor (F) 3.40 17.75 9.90 102.57
0 1.025 3.50 18.54 10.00 104.40
0.05 1.126 3.60 19.34 10.20 108.10
0.10 1.230 3.70 20.16 10.40 111.87
0.15 1.339 3.80 21.00 10.60 115.70
0.20 1.453 3.90 21.85 10.80 119.59
0.25 1.572 4.00 22.72 11.00 123.54
0.30 1.694 4.10 23.61 11.20 127.56
0.35 1.822 4.20 24.51 11.40 131.64
0.40 1.953 4.30 25.43 11.60 135.78
0.45 2.090 4.40 26.36 11.80 139.98
0.50 2.230 4.50 27.32 12.00 144.25
0.55 2.375 4.60 28.28 12.20 148.57
0.60 2.525 4.70 29.27 12.40 152.96
0.65 2.679 4.80 30.27 12.60 157.41
0.70 2.837 4.90 31.29 12.80 161.92
0.75 2.999 5.00 32.32 13.00 166.50
0.80 3.166 5.10 33.37 13.20 171.13
0.85 3.338 5.20 34.44 13.40 175.83
0.90 3.514 5.30 35.52 13.60 180.58
0.95 3.694 5.40 36.62 13.80 185.40
1.00 3.878 5.50 37.73 14.00 190.29
1.05 4.067 5.60 38.86 14.20 195.23
1.10 4.260 5.70 40.01 14.40 200.23
1.15 4.458 5.80 41.17 14.60 205.30
1.20 4.660 5.90 42.35 14.80 210.42
1.25 4.866 6.00 43.54 15.00 215.61
1.30 5.076 6.10 44.76 15.20 220.86
1.35 5.291 6.20 45.98 15.40 226.17
1.40 5.510 6.30 47.23 15.60 231.50
1.45 5.734 6.40 48.48 15.80 236.97
1.50 5.961 6.50 49.76 16.00 242.46
1.55 6.193 6.60 51.05 16.20 248.01
1.60 6.429 6.70 52.36 16.40 253.62
1.65 6.670 6.80 53.68 16.60 259.30
1.70 6.915 6.90 55.02 16.80 265.03
1.75 7.164 7.00 56.38 17.00 270.83
1.80 7.417 7.10 57.75 17.20 276.69
1.85 7.675 7.20 59.13 17.40 282.60
1.90 7.937 7.30 60.54 17.60 288.58
1.95 8.203 7.40 61.96 17.80 294.52
2.00 8.473 7.50 63.39 18.00 300.72

The Steam and Condensate Loop 10.2.13

Block 10 Steam Distribution Pipes and Pipe Sizing Module 10.2

Table 10.2.6 Pipeline capacity and pressure factor table

Pipe size (mm)
Factor 15 20 25 32 40 50 65 80 100 150 200 250 300
F
Capacity (kg /h)
0.00016 30.40 55.41 90.72 199.1 598.2 1 275 2 329 3 800
0.00020 16.18 34.32 62.77 103.0 225.6 662.0 1 437 2 623 4 276
0.00025 10.84 17.92 38.19 69.31 113.2 249.9 735.5 1 678 2 904 4 715
0.00030 11.95 19.31 41.83 75.85 124.1 271.2 804.5 1 733 4 172 5 149
0.00035 6.86 12.44 20.59 43.76 80.24 130.0 285.3 845.3 1 823 3 346 5 406
0.00045 3.62 7.94 14.56 23.39 50.75 92.68 150.9 333.2 979.7 2 118 3 884 6 267
0.00055 4.04 8.99 16.18 26.52 57.09 103.8 170.8 373.1 1 101 2 382 4 338 7 057
0.00065 4.46 9.56 17.76 29.14 62.38 113.8 186.7 409.8 1 207 2 595 4 781 7 741
0.00075 4.87 10.57 19.31 31.72 68.04 124.1 203.2 445.9 1 315 2 836 5 172 8 367
0.00085 5.52 11.98 21.88 35.95 77.11 140.7 230.2 505.4 1 490 3 215 5 861 9 482
0.00100 1.96 5.84 12.75 23.50 38.25 81.89 148.6 245.2 539.4 1 579 3 383 6 228 10 052
0.00125 2.10 6.26 13.57 24.96 40.72 87.57 159.8 261.8 577.9 1 699 3 634 6 655 10 639
0.00150 2.39 7.35 15.17 28.04 45.97 98.84 179.3 295.1 652.8 1 908 4 091 7 493 11 999
0.00175 2.48 7.51 16.30 29.61 49.34 103.4 188.8 311.1 686.5 2 017 4 291 7 852 13 087
0.0020 2.84 8.58 18.63 33.83 56.39 118.2 215.8 355.5 784.6 2 305 4 904 8 974 14 956
0.0025 3.16 9.48 20.75 37.25 61.30 132.0 240.5 391.3 881.7 2 456 5 422 10 090 16 503
0.0030 3.44 10.34 22.5 40.45 66.66 143.4 262.0 429.8 924.4 2 767 6 068 11 033 18 021
0.0040 4.17 12.50 26.97 48.55 80.91 173.1 313.8 514.9 1 128 3 330 7 208 13 240 21 625
0.0050 4.71 14.12 30.40 54.92 90.23 196.1 354.0 578.6 1 275 3 727 8 189 14 858 24 469
0.0060 5.25 15.69 35.80 60.31 99.05 215.8 392.3 647.3 1 412 4 148 9 072 16 476 26 970
0.0080 6.08 18.34 39.23 70.12 116.2 251.5 456.0 750.3 1 648 4 879 10 543 19 173 31 384
0.0100 6.86 20.64 44.13 79.44 130.4 283.9 514.9 845.9 1 863 5 492 11 867 21 576 35 307
0.0125 7.35 22.20 47.28 81.00 140.1 302.1 547.3 901.9 1 983 5 867 12 697 23 074 37 785
0.0150 8.27 25.00 53.33 95.62 157.2 342.0 620.6 1 020 2 230 6 620 14 251 25 974 42 616
0.0175 8.58 26.39 55.78 100.4 165.6 360.4 665.1 1 073 2 360 6 994 15 017 27 461 44 194
0.0200 9.80 30.16 63.75 114.7 189.3 411.9 760.1 1 226 2 697 7 993 17 163 31 384 50 508
0.0250 10.99 33.48 70.73 127.3 209.8 459.7 834.6 1 367 2 970 8 817 19 332 34 750 56 581
0.0300 12.00 36.78 77.23 137.9 229.9 501.1 919.4 1 480 3 264 9 792 20 917 37 697 62 522
0.0400 14.46 44.16 93.17 169.2 279.5 600.7 1 093 1 790 3 923 11 622 25 254 45 604 75 026
0.0500 16.43 49.53 104.4 191.2 313.8 676.7 1 231 2 020 4 413 13 044 28 441 51 489 85 324
0.060 18.14 52.96 115.7 210.8 343.2 750.3 1 373 2 231 4 855 14 368 31 384 57 373
0.080 21.08 62.28 134.8 245.2 402.1 872.8 1 594 2 599 5 688 16 672 36 532
0.100 24.03 70.12 152.0 277.0 456.0 980.7 1 804 2 942 6 424 18 879
0.120 25.99 77.48 167.7 306.5 500.2 1 079 1 986 3 236 7 110 20 841
0.150 28.50 84.13 183.9 334.2 551.7 1 195 2 161 3 494 7 769
0.200 34.32 102.0 220.7 402.1 622.0 1 427 2 599 4 217 9 317
0.250 37.72 112.7 245.2 447.9 735.5 1 565 2 876 4 668
0.300 41.37 122.7 266.6 487.3 804.5 1 710 3 126 5 057
0.350 43.34 128.7 283.2 514.9 841.0 1 802 3 2.61
0.400 49.93 147.1 323.6 588.4 961.1 2 059 3 727
0.450 50.31 150.0 326.6 600.2 979.9 2 083
0.500 55.90 166.7 362.9 666.9 1 089 23 214
0.600 62.28 185.3 402.1 735.5 1 201
0.700 63.07 188.8 407.6 750.9
0.800 72.08 215.8 465.8 858.1
0.900 73.28 218.4 476.6

10.2.14 The Steam and Condensate Loop

Block 10 Steam Distribution Pipes and Pipe Sizing Module 10.2

Table 10.2.7 Steam pipeline sizing chart - Pressure drop

20

10

10
3

15
2

20
25
30
Pressure loss bar/100 m

40
1

50
60
70
80
100
0.5

125
15 0

mm
200
0.3

250
300

eter
0.2

400
500

diam
ipe 600
0.1

de p
0.05

Insi
0.03
0.02

0.01

Steam pressure bar g

cuum
50% va
g
0 bar
10
20
30

0.5
50

1
100
200
300

2
5 00

3
100

3 00 0
0
2 00

5
0
5 00

00

7
30 0000
10 0

h
00
10

kg /
00
20

000
50 0
15

rate
flow 0
am 00 00
Saturation
100
20
temperature
30
2
curve
50
Ste

70
100

100 200 300 400 500

Steam temperature °C

The Steam and Condensate Loop 10.2.15

Block 10 Steam Distribution Pipes and Pipe Sizing Module 10.2

Table 10.2.8 Steam pipeline sizing chart - Velocity

600
500
400

300

/s 200
m
ity
loc
ve 5
m
ea

Pipe diameter mm
St 10 100
20
30
50
0
10 50
1 50
40

30

20

10 Steam pressure bar g

/h
kg
te cuum
ra 50% va
w 0
flo 1
ea
m 20 0 0 bar g
St 3
50 0.5
0 1
10
0 2
20 00
3 0 3
50 5
00
10 7
00 10
2 0 000
3 00 15
50 0 20
00 Saturation
10 0 temperature 30
00 0
20 00 0 curve
30 00 50
50 00 70
000
1 00 100
000
2

100 200 300 400 500

Steam temperature °C

10.2.16 The Steam and Condensate Loop

Block 10 Steam Distribution Pipes and Pipe Sizing Module 10.2

Questions

1. A boiler is operated at 10 bar g and is required to supply 500 kg /h of saturated steam at

9.8 bar g to equipment 110 m away. The pipe run is torturous and contains many fittings
adding 20% to the equivalent length. What size pipe should be selected?
a | 100 mm nominal bore ¨
b | 80 mm nominal bore ¨
c | 50 mm nominal bore ¨
d | 65 mm nominal bore ¨

2. A 100 mm steam pipe has been selected for a particular steam flowrate with
8.3 bar g at the inlet and 7.7 bar g at the end of the run. Calculations show that, for
this flowrate and size of pipe, the pressure at the end of the run will actually be
7.9 bar g. Which of the following is true?
a | The steam velocity is higher than expected, and could cause noise ¨
b | The pipe has some additional spare capacity for future additional loads ¨
c | The resistance to flow is higher than expected ¨
d | A larger pipe is required ¨
3. A 40 m long 5 bar g saturated steam pipe is to be sized to carry 850 kg /h of steam.
Should the pipe be sized on velocity or pressure drop?
a | Pressure drop to limit the steam velocity ¨
b | On a velocity over 40 m/s ¨
c | On a velocity of about 25 m/s ¨
d | Either, provided the steam velocity does not exceed, approximately 5 m /s ¨

4. A 40 m pipe incorporating a number of bends and fittings is to be sized by the velocity

method to handle 1 200 kg /h of saturated steam at 4 bar g. What size pipe is required?
a | 100 mm ¨
b | 80 mm ¨
c | 125 mm ¨
d | The pipe should be sized on pressure drop, and not by velocity ¨

5. A straight run of pipe 30 m long and carrying saturated steam at 10 bar g is to be sized
by the velocity method to pass 20 000 kg /h. What size pipe is required?
a | 175 mm ¨
b | 150 mm ¨
c | 200 mm ¨
d | 250 mm ¨

6. From the following, what is the effect of sizing a 100 m long, 8 bar g steam pipe by the
velocity method?
a | Sizing by velocity takes no account of pressure drop along the pipe ¨
b | If the velocity is more than 40 m /s, the pressure drop along the pipe may be
very small and in practice a small pipe may be used ¨
c | If a low velocity is selected, the chosen pipe will probably be undersized resulting
in steam starvation at the plant ¨
d | Over a length of 100 m, the noise of steam flow can be unacceptable ¨
Answers
1: d, 2: b, 3: c, 4: a, 5: d, 6: a

The Steam and Condensate Loop 10.2.17

Block 10 Steam Distribution Pipes and Pipe Sizing Module 10.2

10.2.18 The Steam and Condensate Loop