How to correctly size steam networks? Learn about the essential components for efficiency and safety

Proper sizing of a steam network is essential to ensure energy efficiency, operational safety, and longer equipment life.

When the system is not designed correctly, thermal losses, increased fuel consumption, premature pipe wear, process failures, and accident risks can occur.

Below are the main sizing criteria and essential components for building an efficient steam network, based on best practices widely used by the industry.

Fundamental criteria for sizing

Inlet pressure and outlet pressure

For pressure reducing stations, it is essential to know the inlet pressure (P1) and outlet pressure (P2). This is necessary for the best specification of the diameters to be applied at the inlet and outlet of the steam reducing/control station, following criteria of velocity and pressure drop (pressure in the steam network), ensuring stability, safety, and better use of the latent heat of the steam.

Flow rate and simultaneity of equipment

It is necessary to identify the total flow rate of the network, “peak consumption,” and the number of pieces of equipment that consume steam simultaneously.

These parameters will determine the size of the pipe diameter and the appropriate selection of valves, as well as the number of drains that should be built into the steam network.

Steam velocity

The recommended velocity in the steam line should be between 25 and 35 m/s. Higher velocities increase noise and cause premature wear of the steam network. Lower velocities favor condensation within the line, contributing to greater condensate formation and generating a higher risk of water hammer.

Essential components of a steam network

Moisture separators

These are responsible for removing moisture, improving steam quality, and directing condensate arriving with the steam to the drain. Particles and debris are retained by the filter, and the condensate is drained at the drainage station.

They work by diverting flow and using differences in density and gravity, allowing the condensate to be directed to the drain. This step ensures drier steam and protects the equipment located after this point in the piping.

Pressure reducing valves

Used to reduce boiler pressure levels to values suitable for the processes, they allow for better energy efficiency and greater operational control of equipment requirements.

The most common versions are:

• Direct acting, simpler and more compact.

• Self-operated, require correct installation of the balance pipe, preferably in a downward direction.

• Control valves, operate via mechanical pilots, electronic controllers, and HMI/PLC.

Y-type or basket filters

Essential for retaining impurities and protecting important components such as valves, steam traps, pumps, and meters. Periodic cleaning of the screens prevents clogging and operational failures.

Drainage system: drain traps and steam traps

The presence of condensate in the line can cause corrosion and water hammer.

Good practices recommend installing drain traps every 30 to 40 meters.

Steam traps, available in mechanical, thermodynamic, and thermostatic versions, automatically remove condensate without steam loss.

Condensate pumps

Used when condensate needs to be lifted to higher levels in the plant or over distances where the pressure differential is insufficient.

Flash tank

The flash tank is used to recover energy from hot condensate, which is water resulting from steam condensation and passes from high pressure to low pressure. Thus, the thermal energy of the liquid is released, instantly transforming part of the water into steam due to the pressure drop.

This process can be used to recover energy, as the steam formed can be captured and reused in industrial applications that use lower pressure and temperature, thus helping to reduce costs and making the steam system more efficient.

An efficient steam network depends on a well-designed project, the proper selection of components, and an installation that follows best practices. In addition, preventive maintenance and periodic inspections are essential to ensure safety, economy, and high operational performance.

If your industry wants to optimize its steam system or review its existing infrastructure, our team is ready to support your project.