3.

HEATER CONDENSATE PIPES

A. Pipeline of Condensate Water from Heater No. 1 to Heater No. 2
P4 =53.665 kPa
t 4=66.296℃
Specific Volume, v 4
From Table 4, (Steam Tables by Keenan, et. al.)
v 4=1.02092 ×10−3 m 3 /kg
Volume Flow Rate,Q
Q=m 4 v 4 =2.8234 kg /s ( 1.02092 ×10−3 m 3 /kg )
Q=2.882×10−3 m3 / s

From section 11.5.1.2 PSME code

For water, 1.5 – 3.0 m/s
Using mean velocity,
V =2.25 m/s
π d2
Q= AV ↔2.882 ×10−3 m 3 /s=2 . 25 m/ s ( )
4
d=0.0404 m

From Table 7-2, p. 136 (Ref. & Air Conditioning by Stoecker, et. al.)
Thus, use schedule 40, seamless steel pipe of nominal size of 40 mm with OD
= 48.26 mm & ID = 40.90 mm.
Actual area:
2
π D 2 π ( 0.04090 )
A= = =1.314 ×10−3 m 2
4 4
Actual velocity of water:
Q 2.882× 10−3 m 3 /s
V= = =2.1933 m/ s
A 1.314 ×10−3 m 2

Pipe insulation:
Pipe from condensate water from heater no. 1 to heater no. 2
T c =k m /h

Condensate Pipes | 167

Where:
T c = critical thickness
k m = thermal conductivity
h = heat transfer coefficient
Diameter of Pipe:
ID=40.90 mm, OD=48.26 mm=1.90∈¿
Temperature of Water ¿ 66.296 ℃=151.3328 ℉
Ambient air temperature ¿ 27 ℃=80.6 ° F
66.296+ 27
T ave = ℃ =46.648 ℃
2
Use Rockwool insulation to be applied to the pipe from thermal insulation
handbook by Thermal Insulation Association of South Africa (TIASA)
t ,℃ k
46.648 km
100 0.044
150 0.051
k m=0.0365 W /m−K
Finding for h,
151.3328+80.6
Tf= ° F=11 5 .9664 ° F
2
From Table A-9E, p. 911 Fluid Mechanics Fundamentals and Applications by Cengel
and Cimbala.
@T f =115 .9664 ° F

ν=1.900 ×10−4 ft 2 /s
k =0.01 57 BTU /h−ft −R
Pr=0.7236
Coefficient of expansion,
1 1 1
β= = =
T f 115 .9664 +460 R 575.9664 R
Diameter of Grashof and Rayleigh numbers are;
3
D 3 gβ ∆t ( 1.90/12 ) ( 32.2 ) (1 /575 .9664 )( 151.3328−80.6 )
Gr D = =
ν2 ( 1.900 ×10−4 )
2

Gr D =434,799.90
RaD =Gr D Pr=434,799.90 ( 0.7236 )

Condensate Pipes | 168

RaD =314,621.21
Then,
2
9 /16 −8/ 27

{
NuD = 0.60+0.387 RaD 1/ 6
[ ( ) ] }
1+
0.559
Pr

NuD =10.5 85
And,
k 0.01 564
h=NuD =10.585 × 5.675W /m2 −K
D 1.90
12
h=5 .956W /m2−K
Thus,
k m 0.03646 W /m−K
T c= =
h 5 .904 W / m2−K
T c =6.128 ×10−3 m=6.128 mm
Recommended thickness of insulation from “the thickness of Rockwool
insulation in accordance with BS5422:2009” at a temperature of 66.296 ℃ and a
pipe diameter of 48.26 mm.
Insulationthickness=24.2703 mm
B. Pipeline of Condensate Water from Heater No. 2 to Heater No. 3
P7=105.991 kPa
t 7=83.175 ℃
Specific Volume, v7
From Table 4, (Steam Tables by Keenan, et. al.)
v7 =1.0313× 10−3 m3 /kg
Volume Flow Rate,Q
Q=m7 v 7 =4.6317 kg /s ( 1.0313× 10−3 m3 /kg )
Q=4.777 ×10−3 m3 /s

From section 11.5.1.2 PSME code

For water, 1.5 – 3.0 m/s
Using mean velocity,
V =2.25 m/s

Condensate Pipes | 169

 π d2
Q= AV ↔ 4.777 ×10−3 m 3 /s=2 . 25 m/s ( )
4
d=0.052m
From Table 7-2, p. 136 (Ref. & Air Conditioning by Stoecker, et. al.)
Thus, use schedule 40, seamless steel pipe of nominal size of 50 mm with OD
= 60.33 mm & ID = 52.51 mm.
Actual area:
2
π D 2 π ( 0.0 52 5 1 )
A= = =2.166× 10−3 m 2
4 4
Actual velocity of water:
Q 4.777 × 10−3 m3 /s
V= = =2.205 m/ s
A 2.166 ×10−3 m2

Pipe insulation:
Pipe from condensate water from heater no. 2 to heater no. 3
T c =k m /h
Where:
T c = critical thickness
k m = thermal conductivity
h = heat transfer coefficient
Diameter of Pipe:
ID=5 2.5 1 mm, OD=60.33 mm=2.37 5∈¿
Temperature of Water ¿ 83.175 ℃=181.715 ℉
Ambient air temperature ¿ 27 ℃=80.6 ° F
83.175+ 27
T ave = ℃=5 5.0875 ℃
2

Use Rockwool insulation to be applied to the pipe from thermal insulation

handbook by Thermal Insulation Association of South Africa (TIASA)
t ,℃ k
55.0875 km
100 0.044
150 0.051
k m=0.0377 W / m−K

Condensate Pipes | 170

Finding for h,
181.715+80.6
Tf= ° F=131.1575 ° F
2

From Table A-9E, p. 911 Fluid Mechanics Fundamentals and Applications by

Cengel and Cimbala.
@T f =129.782° F
ν=1.988 ×10−4 ft 2 /s
k =0.01 6 BTU /h−ft −R
Pr=0.7214
Coefficient of expansion,
1 1 1
β= = =
T f 131.1575+ 460 R 591.1575 R
Diameter of Grashof and Rayleigh numbers are;
3
D 3 gβ ∆t ( 2.37 5/12 ) ( 32.2 ) (1 /591.1575 )( 181.715−80.6 )
Gr D = =
ν2 ( 1.9800 ×10−4 )
2

Gr D =1,089,143.18
RaD =Gr D Pr=1,089,143.18 ( 0.7214 )
RaD =785,707.89
Then,
2
9 /16 −8/ 27

{
NuD = 0.60+0.387 RaD 1/ 6
[ ( ) ] }
1+
0.559
Pr

NuD =13. 616

And,
k 0.01598
h=NuD =13.522 ×5.675 W / m2−K
D 2.37 5
12
h=6.247 W /m2−K
Thus,
k m 0.03761W /m−K
T c= =
h 6.196 W /m 2−K
T c =6.035 ×10−3 m=6.035 mm

Condensate Pipes | 171

 Recommended thickness of insulation from “the thickness of Rockwool
insulation in accordance with BS5422:2009” at a temperature of 83.175℃ and a
pipe diameter of 60.33 mm.
Insulationthickness =27.9715 m
C. Pipeline of Condensate Water from Heater No. 3 to Deaerator
P10=137.592 kPa
t 10=101.287 ℃
Specific Volume, v10
From Table 4, (Steam Tables by Keenan, et. al.)
v10 =1.0446× 10−3 m 3 /kg
Volume Flow Rate,Q
Q=m10 v 10=6.5457 kg/s ( 1.0446× 10−3 m3 /kg )
Q=6.838× 10−3 m3 /s

From section 11.5.1.2 PSME code

For water, 1.5 – 3.0 m/s
Using mean velocity,
V =2.25 m/s
π d2
Q= AV ↔6.838 ×10−3 m3 / s=2. 2 5 m/s ( )
4
d=0.0622m

From Table 7-2, p. 136 (Ref. & Air Conditioning by Stoecker, et. al.)
Thus, use schedule 40, seamless steel pipe of nominal size of 60 mm with OD
= 73.03 mm & ID = 62.65 mm.
Actual area:
2
π D2 π ( 0.06265 )
A= = =3.083× 10−3 m2
4 4
Actual velocity of water:
Q 6.838 ×10−3 m 3 /s
V= = =2.218 m/s
A 3.083 ×10−3 m 2

Pipe insulation:
Pipe from condensate water from heater no. 3 to deaerator
Condensate Pipes | 172
T c =k m /h

Where:
T c = critical thickness
k m = thermal conductivity
h = heat transfer coefficient
Diameter of Pipe:
ID=6 2.6 5 mm, OD=73.03 mm=2.875∈¿
Temperature of Water ¿ 101.287 ℃=214.3166 ℉
Ambient air temperature ¿ 27 ℃=80.6 ° F
101.287+ 27
T ave = ℃=64.1435℃
2

Use Rockwool insulation to be applied to the pipe from thermal insulation

handbook by Thermal Insulation Association of South Africa (TIASA)
t ,℃ k
64.1435 km
100 0.044
150 0.051
k m=0.039 W /m−K
Finding for h,
214.3166+ 80.6
Tf= ° F=147.4583 ° F
2

From Table A-9E, p. 911 Fluid Mechanics Fundamentals and Applications by

Cengel and Cimbala.
@T f =144.636 ° F

ν=2.084 ×10−4 ft 2 / s
k =0.01 6 BTU /h−ft −R
Pr=0.719
Coefficient of expansion,
1 1 1
β= = =
T f 147.4583+ 460 R 607.4583 R
Diameter of Grashof and Rayleigh numbers are;

Condensate Pipes | 173

 3
D 3 gβ ∆t ( 2.87 5/12 ) ( 32.2 ) (1 /607.4583 )( 214.3166−80.6 )
Gr D = =
ν2 ( 2.084 × 10−4 )
2

Gr D =2,244,394.04
RaD =Gr D Pr=2,244,394.04 ( 0.719 )
RaD =1,613,719.31
Then,
2
9 /16 −8/ 27

{
NuD = 0.60+0.387 RaD 1/ 6
[ ( ) ] }
1+
0.559
Pr

NuD =16.67
And,
k 0.016
h=NuD =16.67 ×5.675 W /m2−K
D 2.87 5
12
h=6.318 W /m2−K
Thus,
k m 0.039 W /m−K
T c= =
h 6.318W /m 2−K
T c =6 .173 ×10−3 m=6.173 mm
Recommended thickness of insulation from “the thickness of Rockwool
insulation in accordance with BS5422:2009” at a temperature of 101.287 ℃ and a
pipe diameter of 73.03 mm.
Insulationthickness =32.8534 mm

D. Pipeline of Condensate Water from Deaerator to Heater No. 4

P13=194.667 kPa
t 13=108.897 ℃
Specific Volume, v13
From Table 4, (Steam Tables by Keenan, et. al.)
v13=1.051×10−3 m3 /kg
Volume Flow Rate,Q
Q=m13 v 13=7.4129 kg /s ( 1.051 ×10−3 m 3 /kg )
Q=7.791 ×10−3 m 3 / s

Condensate Pipes | 174

From section 11.5.1.2 PSME code
For water, 1.5 – 3.0 m/s
Using mean velocity,
V =2.25 m/s
π d2
Q= AV ↔7.791 ×10−3 m 3 /s=2 . 25 m/s ( )
4
d=0.066 m
From Table 7-2, p. 136 (Ref. & Air Conditioning by Stoecker, et. al.)
Thus, use schedule 40, seamless steel pipe of nominal size of 60 mm with OD
= 73.03 mm & ID = 62.65 mm.
Actual area:
2 2
π D π ( 0.06265 )
A= = =3.083× 10−3 m 2
4 4
Actual velocity of water:
Q 7.791× 10−3 m 3 /s
V= = =2.527 m/s
A 3.083 ×10−3 m 2

Pipe insulation:
Pipe from condensate water from deaerator to heater no. 4
T c =k m /h
Where:
T c = critical thickness
k m = thermal conductivity
h = heat transfer coefficient
Diameter of Pipe:
ID=6 2.6 5 mm, OD=73.03 mm=2.875∈¿
Temperature of Water ¿ 108.897=228.015℉
Ambient air temperature ¿ 27 ℃=80.6 ° F
108.897+ 27
T ave = ℃=67.949℃
2

Use Rockwool insulation to be applied to the pipe from thermal insulation

handbook by Thermal Insulation Association of South Africa (TIASA)

Condensate Pipes | 175

 t ,℃ k
67.949 km
100 0.044
150 0.051
k m=0.03951 W /m−K
Finding for h,
228.015+80.6
Tf= ° F=1 5 4.3075 ° F
2

From Table A-9E, p. 911 Fluid Mechanics Fundamentals and Applications by

Cengel and Cimbala.
@T f =1 5 4.3075° F

ν=2.125 ×10−4 ft 2 /s
k =0.01 7 BTU /h−ft −R
Pr=0.718
Coefficient of expansion,
1 1 1
β= = =
T f 15 4.3075+ 460 R 614.3075 R
Diameter of Grashof and Rayleigh numbers are;
3
D 3 gβ ∆t ( 2.87 5/12 ) ( 32.2 ) (1 /614.3075 )( 228.015−80.6 )
Gr D = =
ν2 ( 2.125 × 10−4 )
2

Gr D =2353226.18
RaD =Gr D Pr=2353226.18 ( 0.718 )
RaD =1689616.4
Then,
2
9 /16 −8/ 27

{
Nu D = 0.60+0.387 RaD 1/ 6
[ ( ) ] }
1+
0.559
Pr

NuD =16.886
And,
k 0.01647
h=NuD =16.886 ×5.675 W /m2−K
D 2.87 5
12
h=6.8 W /m 2−K
Thus,

Condensate Pipes | 176

 k m 0.03951W /m−K
T c= =
h 6.8 W /m 2−K
T c =5.81× 10−3 m=5.81 mm
Recommended thickness of insulation from “the thickness of Rockwool
insulation in accordance with BS5422:2009” at a temperature of 108.897 ℃ and a
pipe diameter of 73.03 mm.
Insulationthickness =33.2845 m
E. Pipeline of Condensate Water from Heater No. 4 to Heater No. 5
P16=274.79 kPa
t 16=119.407 ℃
Specific Volume, v16
From Table 4, (Steam Tables by Keenan, et. al.)
v16 =1.05 93× 10−3 m3 /kg
Volume Flow Rate,Q
Q=m16 v 16=8.5549 kg/s ( 1.05 93× 10−3 m 3 /kg )
Q=9.0622× 10−3 m3 / s

From section 11.5.1.2 PSME code

For water, 1.5 – 3.0 m/s
Using mean velocity,
V =2.25 m/s
π d2
Q= AV ↔ 9.0622×10−3 m3 / s=2. 2 5 m/ s ( )4
d=0.072m

From Table 7-2, p. 136 (Ref. & Air Conditioning by Stoecker, et. al.)
Thus, use schedule 40, seamless steel pipe of nominal size of 75 mm with OD
= 88.90 mm & ID = 77.92 mm.
Actual area:
2
π D 2 π ( 0.07792 )
A= = =4.769 ×10−3 m 2
4 4
Actual velocity of water:
Q 9.0622 ×10−3 m 3 /s
V= = =1.9 m/s
A 4.769 ×10−3 m 2
Condensate Pipes | 177
Pipe insulation:
Pipe from condensate water from heater no. 4 to heater no. 5
T c =k m /h
Where:
T c = critical thickness
k m = thermal conductivity
h = heat transfer coefficient
Diameter of Pipe:
ID=77.92mm, OD=88.90 mm=3.5∈¿
Temperature of Water ¿ 119.407=246.933 ℉
Ambient air temperature ¿ 27 ℃=80.6 ° F
119.407 +27
T ave = ℃ =73.204 ℃
2

Use Rockwool insulation to be applied to the pipe from thermal insulation

handbook by Thermal Insulation Association of South Africa (TIASA)
t ,℃ k
73.204 km
100 0.044
150 0.051
k m=0.04025 W /m−K
Finding for h,
24 6.933+ 80.6
Tf= ° F=163.767 ° F
2

From Table A-9E, p. 911 Fluid Mechanics Fundamentals and Applications by

Cengel and Cimbala.
@T f =1 63.767° F
ν=2.182× 10−4 ft 2 /s
k =0.01 7 BTU /h−ft −R
Pr=0.7169
Coefficient of expansion,

Condensate Pipes | 178

 1 1 1
β= = =
T f 163.767+ 460 R 623.767 R
Diameter of Grashof and Rayleigh numbers are;
3
D 3 gβ ∆t ( 3.5 0/12 ) ( 32.2 ) (1 /623.767 )( 246.993−80.6 )
Gr D = =
ν2 ( 2.182× 10−4 )
2

Gr D =4476302.54
RaD =Gr D Pr=4476302.54 ( 0.7169 )
RaD =3209061.29
Then,
2
9 /16 −8/ 27

{
NuD = 0.60+0.387 RaD 1/ 6
[ ( ) ] }
1+
0.559
Pr

NuD =20.294
And,
k 0.01676
h=NuD =20.294 ×5.675 W /m2−K
D 3.50
12
h=6.713 W / m2−K
Thus,
k m 0.04025W /m−K
T c= =
h 6.713 W /m 2−K
T c =5.996 ×10−3 m=5.996 mm
Recommended thickness of insulation from “the thickness of Rockwool
insulation in accordance with BS5422:2009” at a temperature of 119.407 ℃ and a
pipe diameter of 88.90 mm.
Insulationthickness =37.8814 mm

F. Pipeline of Condensate Water from Heater No. 5 to Heater No. 6

P19=366.778 kPa
t 19=130.728 ℃
Specific Volume, v19
From Table 4, (Steam Tables by Keenan, et. al.)
v19=1.0707 × 10−3 m3 / kg
Volume Flow Rate,Q

Condensate Pipes | 179

Q=m19 v 19=9.8556 kg/s ( 1.0707 × 10−3 m 3 /kg )
Q=10.552 ×10−3 m3 /s

From section 11.5.1.2 PSME code

For water, 1.5 – 3.0 m/s
Using mean velocity,
V =2.25 m/s
π d2
Q= AV ↔10.552 ×10−3 m 3 /s=2 . 25 m/s ( )4
d=0.077 m

From Table 7-2, p. 136 (Ref. & Air Conditioning by Stoecker, et. al.)
Thus, use schedule 40, seamless steel pipe of nominal size of 75 mm with OD
= 88.90 mm & ID = 77.92 mm.
Actual area:
2
π D 2 π ( 0.07792 )
A= = =4.769 ×10−3 m 2
4 4
Actual velocity of water:
Q 10.552× 10−3 m 3 /s
V= = =2.213m/ s
A 4.769 ×10−3 m 2

Pipe insulation:
Pipe from condensate water from heater no. 5 to heater no. 6
T c =k m /h
Where:
T c = critical thickness
k m = thermal conductivity
h = heat transfer coefficient
Diameter of Pipe:
ID=77.92mm, OD=88.90 mm=3.5∈¿
Temperature of Water ¿ 130.728=267.31 ℉
Ambient air temperature ¿ 27 ℃=80.6 ° F

Condensate Pipes | 180

 130. 728+27
T ave = ℃=78.864 ℃
2

Use Rockwool insulation to be applied to the pipe from thermal insulation

handbook by Thermal Insulation Association of South Africa (TIASA)
t ,℃ k
78.864 km
100 0.044
150 0.051
k m=0.04104 W /m−K
Finding for h,
267.31+80.6
Tf= ° F=1 73.955° F
2

From Table A-9E, p. 911 Fluid Mechanics Fundamentals and Applications by

Cengel and Cimbala.
@T f =1 73.955° F

ν=2.244 ×10−4 ft 2 / s
k =0.01 7 BTU /h−ft −R
Pr=0.71 56
Coefficient of expansion,
1 1 1
β= = =
T f 173.955+ 460 R 633.955 R
Diameter of Grashof and Rayleigh numbers are;
3
D 3 gβ ∆t ( 3.5 0/12 ) ( 32.2 ) (1 /633.955 )( 267.31−80.6 )
Gr D = =
ν2 ( 2.244 × 10−4 )
2

Gr D =4672827.07
RaD =Gr D Pr=4672827.07 ( 0.71 5 6 )
RaD =3343875.05
Then,
2
9 /16 −8/ 27

{
Nu D = 0.60+0.387 RaD 1/ 6
[ ( ) ] }
1+
0.559
Pr

NuD =20. 531

And,

Condensate Pipes | 181

 k 0.01701
h=NuD =20.5 31 × 5.675W /m2−K
D 3. 50
12
h=6.791W /m 2−K

Thus,
k m 0.04104 W /m−K
T c= =
h 6.791W /m2−K
T c =6.043 ×10−3 m=5 .883 mm
Recommended thickness of insulation from “the thickness of Rockwool
insulation in accordance with BS5422:2009” at a temperature of 130.728 ℃ and a
pipe diameter of 88.90 mm.
Insulationthickness =40.1456 mm

G. Pipeline of Condensate Water from Heater No. 6 to Hot well

P21=366.778 kPa
t 21=140.531℃
Specific Volume, v 21
From Table 2, (Steam Tables by Keenan, et. al.)
v 21=1.0803 ×10−3 m3 /kg
Volume Flow Rate,Q
Q=m21 v 21=11.04 kg/ s ( 1.0803 ×10−3 m3 /kg )
Q=0.01193 m 3 /s

From section 11.5.1.2 PSME code

For water, 1.5 – 3.0 m/s
Using mean velocity,
V =2.25 m/s
π d2
Q= AV ↔0.01193 m3 /s=2 .2 5 m/s ( )4
d=0.082m

From Table 7-2, p. 136 (Ref. & Air Conditioning by Stoecker, et. al.)

Condensate Pipes | 182

 Thus, use schedule 40, seamless steel pipe of nominal size of 75 mm with OD
= 88.90 mm & ID = 77.92 mm.
Actual area:
2
π D 2 π ( 0.07792 )
A= = =4.769 ×10−3 m 2
4 4

Actual velocity of water:

Q 0.01193 m 3 / s
V= = =2.502 m/s
A 4.769 ×10−3 m2

Pipe insulation:
Pipe from condensate water from heater no. 6 to hotwell
T c =k m /h
Where:
T c = critical thickness
k m = thermal conductivity
h = heat transfer coefficient
Diameter of Pipe:
ID=77.92mm, OD=88.90 mm=3.5∈¿
Temperature of Water ¿ 140.531℃ =284.956 ℉
Ambient air temperature ¿ 27 ℃=80.6 ° F
140.531+27
T ave = ℃=83.766 ℃
2

Use Rockwool insulation to be applied to the pipe from thermal insulation

handbook by Thermal Insulation Association of South Africa (TIASA)
t ,℃ k
83.766 km
100 0.044
150 0.051
k m=0.041 73W /m−K
Finding for h,
284.956+ 80.6
Tf= ° F=182.778 ° F
2

Condensate Pipes | 183

 From Table A-9E, p. 911 Fluid Mechanics Fundamentals and Applications by
Cengel and Cimbala.
@T f =1 82.778° F
ν=2.298 ×10−4 ft 2 /s
k =0.01 72 BTU /h−ft−R
Pr=0.71 4 5
Coefficient of expansion,
1 1 1
β= = =
T f 182.778+ 460 R 642.778 R
Diameter of Grashof and Rayleigh numbers are;
3
D 3 gβ ∆t ( 3.5 0/ 12 ) ( 32.2 ) (1 /642.778 )( 284.956−80.6 )
Gr D = =
ν2 ( 2.289× 10−4 )
2

Gr D =4,847,871.18
RaD =Gr D Pr=4,847,871.18 ( 0.71 4 0 )
RaD =3,461,380,02
Then,
2
9 /16 −8/ 27

{
NuD = 0.60+0.387 RaD 1/ 6
[ ( ) ] }
1+
0.559
Pr

NuD =20. 731

And,
k 0.01 70
h=NuD =20.731 × 5.675W /m2−K
D 3. 50
12
h=6.857 W /m2−K
Thus,
k m 0.04173 W /m−K
T c= =
h 6.857 W /m 2−K
T c =6 .085 ×10−3 m=6.085 mm
Recommended thickness of insulation from “the thickness of Rockwool
insulation in accordance with BS5422:2009” at a temperature of 140.531 ℃ and a
pipe diameter of 88.90 mm.
Insulationthickness =42.1062 mm

H. Pipeline of Condensate Water from Evaporator to Hotwell

Condensate Pipes | 184

P3 8=366.778 kPa
t 3 8=140.531℃
Specific Volume, v35
From Table 2, (Steam Tables by Keenan, et. al.)01
v3 5 =1.0803× 10−3 m3 /kg
Volume Flow Rate,Q
Q=m3 8 v 3 8=0.9306 kg/ s ( 1.0803 ×10−3 m 3 /kg )
Q=10.053 ×10−4 m3 /s

From section 11.5.1.2 PSME code

For water, 1.5 – 3.0 m/s
Using mean velocity,
V =2.25 m/s
π d2
Q= AV ↔10.053 ×10−4 m 3 /s=2 .2 5 m/s ( )
4
d=0.024 m

From Table 7-2, p. 136 (Ref. & Air Conditioning by Stoecker, et. al.)
Thus, use schedule 40, seamless steel pipe of nominal size of 20 mm with OD
= 26.67 mm & ID = 20.93 mm.
Actual area:
2
π D 2 π ( 0.02093 )
A= = =3.441× 10−4 m 2
4 4
Actual velocity of water:
Q 10.053 ×10−4 m3 / s
V= = =2.922 m/s
A 3.441 ×10−4 m2

Pipe insulation:
Pipe from condensate water from evaporator to hotwell
T c =k m /h
Where:
T c = critical thickness
k m = thermal conductivity

Condensate Pipes | 185

 h = heat transfer coefficient
Diameter of Pipe:
ID=20.93 mm, OD=26.67 mm=1.05∈¿
Temperature of Water ¿ 140.531℃ =284.956 ℉
Ambient air temperature ¿ 27 ℃=80.6 ° F
140.531+27
T ave = ℃=83.766 ℃
2
Use Rockwool insulation to be applied to the pipe from thermal insulation
handbook by Thermal Insulation Association of South Africa (TIASA)
t ,℃ k
83.766 km
100 0.044
150 0.051
k m=0.041 73W /m−K
Finding for h,
284.956+ 80.6
Tf= ° F=182.778° F
2

From Table A-9E, p. 911 Fluid Mechanics Fundamentals and Applications by

Cengel and Cimbala.
@T f =1 82.778° F

ν=2.298 ×10−4 ft 3 /s
k =0.01 72 BTU /h−ft−R
Pr=0.71 4 5
Coefficient of expansion,
1 1 1
β= = =
T f 182.778+ 460 R 642.778 R
Diameter of Grashof and Rayleigh numbers are;
3
D 3 gβ ∆t ( 1.05/12 ) ( 32.2 ) (1 /642.778 )( 284.956−80.6 )
Gr D = =
ν2 ( 2.298× 10−4 )
2

Gr D =129869.26
RaD =Gr D Pr=129869.26 ( 0.7145 )
RaD =92791.59
Then,

Condensate Pipes | 186

 2
9 /16 −8/ 27

{
Nu D = 0.60+0.387 RaD 1/ 6
[ ( ) ] }
1+
0.559
Pr

NuD =7.633
And,
k 0.01717
h=NuD =7.633 × 5.675W /m2−K
D 1.05
12
h=8.515 W /m 2−K
Thus,
k m 0.04173 W /m−K
T c= =
h 8.515 W /m 2−K
T c =4.901 ×10−3 m=4.901 mm
Recommended thickness of insulation from “the thickness of Rockwool
insulation in accordance with BS5422:2009” at a temperature of 140.531 ℃ and a
pipe diameter of 26.67 mm.
Insulationthickness =32.0797 mm
I. Pipeline of Condensate Water from Evaporator to Cooling Tower
P41=6.865 kPa
t 41=34.4301℃
Specific Volume, v 41
From Table 1, (Steam Tables by Keenan, et. al.)
v 41=1.005 8 × 10−3 m3 / kg
Volume Flow Rate,Q
Q=m41 v 41= (1418.5813 kg /s ) ( 1.005 8 ×10−3 m3 /kg )
Q=1.427 m3 / s

From section 11.5.1.2 PSME code

For water, 1.5 – 3.0 m/s
Using mean velocity,
V =2.25 m/s
π d2
Q= AV ↔1.427 m3 /s=2 . 25 m/ s ( )
4
d=0.899 m

Condensate Pipes | 187

From Fig A-6 Pipe Standards, p. 665 (PPE by Morse)
Thus, use schedule 40, 2 seamless steel pipes of 457.2 mm OD and 428.64 mm
ID.
Actual area:
2
π D 2 π ( 0.42864 )
A= = × 2=0.28861 m 2
4 4
Actual velocity of water:
Q 1.427 m 3 /s
V= = ÷ 2=2.472m/ s
A 0.28861 m2
Pipe insulation:
Pipe for evaporator blowdown
T c =k m /h
Where:
T c = critical thickness
k m = thermal conductivity
h = heat transfer coefficient
Diameter of Pipe:
ID=428.64 mm, OD=4 57.2mm=18∈¿
Temperature of Water ¿ 34.4301℃ =93.974 ℉
Ambient air temperature ¿ 27 ℃=80.6 ℉
34.4301+27
T ave = ℃=30.71 5℃
2
Use Rockwool insulation to be applied to the pipe from thermal insulation
handbook by Thermal Insulation Association of South Africa (TIASA)
t ,℃ k
30.715 km
100 0.044
150 0.051
k m=0.03430 W /m−K
Finding for h,
93.974 +80.6
Tf= ℉ =8 7.287 ℉
2
From Table A-9E, p. 911 Fluid Mechanics Fundamentals and Applications by
Cengel and Cimbala.

Condensate Pipes | 188

@T f =8 7.287 ℉
ν=1.7378 ×10−4 ft 3 /s
k =0.01498 BTU /h−ft −R
Pr=0.7279
Coefficient of expansion,
1 1 1
β= = =
T f 8 7 .827+ 460 R 5 4 7 . 827 R
Diameter of Grashof and Rayleigh numbers are;
1
Gr D =
3
D gβ ∆t
=
( 18/12 )3 ( 32.2 ) ( 5 47.827 ) ( 93.974−80.6 )
ν2 2
( 1.7378× 10−4 )
Gr D =83 923 583.84
RaD =Gr D Pr=83 923 583.84 ( 0.7279 )
RaD =61 087 976.68
Then,
2
9 /16 −8/ 27

{
Nu D = 0.60+0.387 RaD 1/ 6
[ ( ) ] }
1+
0.559
Pr

NuD =48.83 5
And,
k 0.01498
h=NuD =48.83 5 ×5.675 W /m2−K
D 18
12
h=2.768 W / m2−K
Thus,
k m 0.03430W /m−K
T c= =
h 2.768 W /m 2−K
T c =12.392× 10−3 m=12.392 mm
Recommended thickness of insulation from “the thickness of Rockwool
insulation in accordance with BS5422:2009” at a temperature of 34.430 ℃ and a
pipe diameter of 457.2 mm.
Insulationthickness=23.1578 mm

J. Pipeline of Condensate Tower from Cooling Water to Evaporator

P43=6.68 5 kPa

Condensate Pipes | 189

t 43=20 ℃
Specific Volume, v 41
From Table 4, (Steam Tables by Keenan, et. al.)
v 41=1.001 8 ×10−3 m 3 /kg
Volume Flow Rate,Q
Q=m43 v 43=( 1418.5813 kg/s ) ( 1.001 8 ×10−3 m3 /kg )
Q=1.421 m3 /s

From section 11.5.1.2 PSME code

For water, 1.5 – 3.0 m/s
Using mean velocity,
V =2.25 m/s
π d2
Q= AV ↔1.421 m3 /s=2 .2 5 m/s ( )
4
d=0.897 m

From Fig A-6 Pipe Standards, p. 665 (PPE by Morse)

Thus, use schedule 40, 2 seamless steel pipes of 457.2 mm OD and 428.64 mm
ID.
Actual area:
2
π D2 π ( 0.42864 )
A= = × 2=0.28861 m2
4 4
Actual velocity of water:
Q 1.421 m3 / s
V= = ÷ 2=2.462m/ s
A 0.28861 m2

Since t 43 < t a , then there is no need for pipe insulation.

Condensate Pipes | 190