Case story
Custom Engineering Solution for High Pressure Clean Steam System
Our client, specializing in detailed engineering within the pharmaceutical industry, faced challenges during the installation of a saturated steam system designed for 18 bar(g) and 210°C. The piping system was stainless steel, but standard fittings had long lead times, which risked delaying the project. To mitigate this, the client manufactured 7 extruded tees for five locations. Our role in the project was to perform a design review of the client’s pipe stress calculation and subsequently provide a solution to the challenge.
Process
The project was executed by our pipe stress engineers in close collaboration with the client.
We carried out pressure calculations for the system, and while these were acceptable, the flexibility analysis revealed that two of the tee positions exceeded utilization limits. Using a standard fitting with greater wall thickness was not an option due to lack of drainability
Therefore, we implemented stub-in tees using available pipe materials (in this case, an ASME material with a dual material certificate, eliminating the need for PMA (Particular Material Appraisal), which is required when a material is not under European standards, but must be verified for chemical consistency). To ensure structural integrity, we performed Finite Element Analysis (FEA) on the two critical positions. At the same time, we ensured quality assurance in accordance with ISO9001.
The project was completed without delays caused by fittings, and the detailed engineering met all safety and compliance requirements.
What is a tee?
A tee is a pipe fitting shaped like the letter “T” and is used either to branch a pipe in two directions or connect three pipelines. There are different types of tees, such as extruded, stub-in, and cast/formed tees.
Extruded tees are where the branch is formed by pressing/extruding material from the main pipe. Stub-in tees are where the branch is welded directly into the main pipe through a cut-out hole. Cast/formed tees are a fitting without welds, made from as uniform a material as possible.
Service and scope of the project
- Design and implementation of a tailored engineering solution for a high-pressure clean steam system
- Flexibility analysis and pressure calculations
- Stub-in design using available materials in compliance with standards
- FEA validation of critical points
- Ensuring compliance and safety requirements under tight deadlines
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