REDUCING THE COST OF REPLACING FAILED CONDENSATE PIPING SYSTEMS

Mr. Larry Stonitsch, President Rovanco Piping Systems, Inc.

Several Ways Steam & Condensate Systems are Installed: Detail A Above Ground

Several Ways Steam & Condensate Systems are Installed: Detail B In a Tunnel

Several Ways Steam & Condensate Systems are Installed: Detail C Shallow Concrete Trench

Several Ways Steam & Condensate Systems are Installed: Detail D Direct Buried Dual Line Conduit

Several Ways Steam & Condensate Systems are Installed: Detail E Direct Buried Single Line Conduit

Direct Buried Dual Line Conduit System Prior to 1970

Both pipes were put into a common conduit because it was less expensive to install one outer protective conduit with several lines in it, i.e. a steam line, a high pressure return and sometimes a gravity return.

Direct Buried Dual Line Conduit System Inefficiencies:

The condensate line would almost always fail far sooner than the steam line. If the condensate line developed leaks there was no way to replace the line without cutting open the outer conduit, replacing the corroded line and closing it up again. If the condensate line was severely corroded it would usually saturate the insulation on the steam line requiring it to be replaced.

Current Day Single Line Direct Buried Steam & Condensate System

It has been found to be more efficient and cost effective, over the life of the steam and condensate systems, to install separate steam and condensate lines.

Current Day Single Line Direct Buried Conduit System Advantages:

If the condensate line fails prior to the steam line, you can replace only the condensate line. The condensate pipe is usually at least half the size of the steam line. The cost to replace only the condensate line is usually 35% of the cost to replace both.

Current Day Direct Buried Single Line Conduit System Disadvantages:

During replacement of the condensate system, the steam system gets damaged. Replacement of only the condensate line is still relatively expensive due to trenching, backfilling & restoration of the trench in addition to the cost of the piping system, approximately $61,000 for material & labor. Replacing both systems triples the cost to approximately $184,000.

Typical Direct Buried Single Line Steam & Condensate System with Expansion Loops

This system is manufactured with expansion loops and the pipe entering manholes and buildings.

Rovanco Designed System with Expansion Joints or Bellows for the Condensate Line

An expansion bellow has been added to the condensate line.

Advantages of Using the Rovanco Designed Condensate System:

Less condensate pipe required. No 90 Elbows required. Material and labor savings of at least 5% as compared to the system with expansion loops.

If the Condensate Line Fails:

Cut a 50 section of pipe out on the end that has expansion bellow or joint. Cut the anchor loose on the opposite end (Detail 3-A).

Cutting Old Carrier Pipe Free Detail 3-A

If the Condensate Line Fails(cont):

The pipe supports are designed with sled runners on all four fins (Detail 3-B cross section). Once the condensate carrier pipe is cut loose, a 40 section can be removed and the rest of the condensate line can be pulled out of the 10 gauge conduit and cut into 40 sections (Detail 3-B). Pulling Old Carrier Pipe Out of Conduit Detail 3-B

If the Condensate Line Fails(cont):

The new condensate pipe can be insulated, inserted into the conduit and tied into the system at each end (Detail 3-C).

Pulling New Carrier Pipe Into Existing Conduit Detail 3-C

If the Condensate Line Fails(cont):

The supports are galvanized so they should be in good condition and may be reused.

Pulling New Carrier Pipe Into Existing Conduit Detail 3-D

Estimated Costs of this Piping System:

Cost of Pipe Cost of Installation

1. 2. 3. 4. 5.

Excavation Installing the pipe Closing up the joints Backfilling Reseeding or paving

NOTE: Cost estimates are based on Drawing 1 (sheet 1 of 4) as a Direct Buried Conduit as per Detail E.

Cost Estimate #1

STEAM LINE 334 lin ft of 8 Schedule 40 Carbon Steel with 2-1/2 of Mineral Wool Insulation in a 16 10 Gauge Steel Conduit with a Fusion Bonded Epoxy Protective Coating 4 90 Elbows 2 Anchors 2 End Seals

CONDENSATE LINE 320 lin ft of 3 Schedule 80 Carbon Steel with 1-1/2 of Mineral Wool Insulation in an 8 10 Gauge Steel Conduit 20 Mil Thick with a Fusion Bonded Epoxy Protective Coating 4 90 Elbows 2 Anchors 2 End Seals

TOTAL INSTALLED COST: including all materials, excavation and backfilling, grading and surface repair, i.e., reseeding or resodding, pipe fitting, welding, pressure testing and commissioning of systems.

$198,000

Cost Estimate #2

STEAM LINE 334 lin ft of 8 Schedule 40 Carbon Steel with 2-1/2 of Mineral Wool Insulation in a 16 10 Gauge Steel Conduit with a Fusion Bonded Epoxy Protective Coating 4 90 Deg Elbows 2 Anchors 2 End Seals

CONDENSATE LINE 300 lin ft of 3 Schedule 80 Carbon Steel with 1-1/2 of Mineral Wool Insulation in an 8 10 Gauge Steel Conduit 20 Mil Thick with a Fusion Bonded Epoxy Protective Coating Expansion Joint/Bellows 2 Anchors 2 End Seals

TOTAL INSTALLED COST: the additional cost for the expansion devise is offset by the elimination of four (4) 90 Elbows, 20 ft of Condensate Line, less excavating, backfill and welding.

$198,000

Cost Estimate #3

Replace Condensate Piping System with expansion loops as shown on Drawing 1 on Sheet 1 of 4. TOTAL INSTALLED COST:

$51,000

Cost Estimate #4

Replace Condensate Piping by cutting out a 50 section and replacing only the condensate pipe and mineral wool insulation. TOTAL INSTALLED COST:

$32,000

Based on our estimates, the savings to the system owner would be $36,000 if this innovation is used to install and replace the condensate line. In addition to the monetary savings, less than 15% of the pipe routing would be excavated. Therefore, the majority of the area would be undisturbed and usable during the repair period. Also, the construction period would be reduced by at least 50% from 30 days to 15 days.

Additional Options for Replacing the Condensate Line

Use a condensate pipe made of Stainless Steel. Additional cost for the condensate pipe shown on drawing 1 would be $4,600.

Use a Schedule 160 Carbon Steel condensate pipe which is 3 times thicker than Schedule 40 and should provide 30% longer life. Additional cost for condensate pipe shown on drawing 1 would be $2,005.

Install condensate receivers in the building or manhole, vent the receivers to reduce pressure and lower the temperature to below 212 F. In this type of system you can send the condensate back to the boiler in a noncorrosive pipe such as PEX or FRP. The initial installed cost of this would be 50% less on drawing 1.

QUESTIONS??
Contact: Mr. Larry Stonitsch or Ms. Brenda Nowatzki 20535 SE Frontage Rd Joliet, Illinois 60431 Tel: (815) 741-6700 Fax (815) 741-4229 larrystone@rovanco.com brendanowatzki@rovanco.com