reducing the cost of replacing failed condensate systems

8/13/2019 Reducing the Cost of Replacing Failed Condensate Systems

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REDUCING THE COST OFREPLACING FAILED

CONDENSATE PIPING

SYSTEMS

Mr. Larry Stonitsch, President

Rovanco Piping Systems, Inc.


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Several Ways Steam & Condensate Systems are

Installed: Detail A Above Ground


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Installed: Detail B In a Tunnel


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Installed: Detail C Shallow Concrete Trench


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Installed: Detail D Direct Buried Dual Line Conduit


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Installed: Detail E Direct Buried Single Line Conduit


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Direct Buried Dual Line Conduit

System Prior to 1970

Both pipes were put into a common conduit because it was less expensive toinstall one outer protective conduit with several lines in it, i.e. a steam line, a

high pressure return and sometimes a gravity return.


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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 andclosing it up again.

If the condensate line was severely corroded it

would usually saturate the insulation on the steamline requiring it to be replaced.


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Current Day Single Line Direct Buried

Steam & Condensate System

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

condensate lines.


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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 costof the piping system, approximately $61,000 formaterial & labor.

Replacing both systems triples the cost toapproximately $184,000.


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Typical Direct Buried Single Line Steam &

Condensate System with Expansion Loops

This system is

manufactured withexpansion loops and

the pipe enteringmanholes and

buildings.


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Rovanco Designed System with Expansion

Joints or Bellows for the Condensate Line

An expansion bellow has been added to the

condensate line.


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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 cutinto 40 sections (Detail 3-B).

Pulling Old Carrier Pipe Out of Conduit Detail 3-B


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If the Condensate Line Fails(cont):The supports are galvanized so they should be in good condition and may bereused.

Pull ing New Carrier Pipe Into Exist ing Conduit Detail 3-D


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Estimated Costs of this Piping

System: Cost of Pipe

Cost of Installation

1. Excavation

2. Installing the pipe

3. Closing up the joints

4. Backfilling

5. Reseeding or paving

NOTE: Cost estimates are based on Drawing 1 (sheet 1 of 4) as a Direct Buried

Conduit as per Detail E.


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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 Coating4 90 Elbows2 Anchors2 End Seals

CONDENSATE LINE320 lin ft of 3 Schedule 80 Carbon Steel with 1-1/2 of Mineral Wool Insulation in an8 10 Gauge Steel Conduit 20 Mil Thick with a Fusion Bonded Epoxy ProtectiveCoating

4 90 Elbows

2 Anchors2 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


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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 Coating4 90 Deg Elbows2 Anchors2 End Seals

CONDENSATE LINE300 lin ft of 3 Schedule 80 Carbon Steel with 1-1/2 of Mineral Wool Insulation in an8 10 Gauge Steel Conduit 20 Mil Thick with a Fusion Bonded Epoxy ProtectiveCoating

Expansion Joint/Bellows

2 Anchors2 End Seals

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

backfill and welding.

$198,000


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Cost Estimate #4 Replace Condensate Piping by cutting out a 50 section and

replacing only the condensate pipe and mineral woolinsulation.

TOTAL INSTALLED COST:

Based on our estimates, the savings to the system ownerwould be $36,000 if this innovation is used to install andreplace the condensate line.

In addition to the monetary savings, less than 15% of the piperouting would be excavated. Therefore, the majority of thearea 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.

$32,000


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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.


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QUESTIONS??

Contact:Mr. Larry Stonitsch

orMs. Brenda Nowatzki20535 SE Frontage Rd

Joliet, Illinois 60431Tel: (815) 741-6700Fax (815) [email protected]@rovanco.com

reducing the cost of replacing failed condensate systems

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