Condensate Pipe Lines - Sizing

Flow and pressure loss in condensate return lines - SI Units. Determine condensate flow rates and pressure losses for various pipe sizes and pressure drops.

Pressure Loss (Pa/m)	Pressure Loss (mbar/m)	15mm (1/2")	20mm (3/4")	25mm (1")	32mm (1 1/4")	40mm (1 1/2")	50mm (2")	65mm (2 1/2")	80mm (3")
28	0.28	90	209	380	865	1320	2554	5194	8079
29	0.29	92	214	400	878	1340	2590	5271	8196
30	0.3	93	218	403	890	1361	2631	5348	8314
33	0.33	97	226	414	930	1420	2744	5579	8677
39	0.39	107	249	469	1028	1565	3025	6142	9526
40	0.4	108	253	476	1040	1583	3062	6214	9639
43	0.43	113	263	496	1079	1646	3180	6454	10024
45	0.45	116	270	508	1107	1687	3261	6618	10297
47	0.47	119	277	521	1134	1728	3338	6777	10523
50	0.5	123	286	538	1172	1787	3447	6949	10859
53	0.53	127	296	557	1211	1846	3565	7235	11249
55	0.55	130	302	569	1238	1887	3638	7380	11476
57	0.57	133	308	580	1261	1923	3710	7525	11703
59	0.59	135	314	591	1288	1959	3783	7666	11884
61	0.61	138	320	602	1311	1996	3851	7806	12111
64	0.64	141	327	615	1338	2041	3933	7970	12383
67	0.67	146	337	634	1379	2100	4051	8210	12746
69	0.69	148	343	645	1402	2136	4119	8342	12973
71	0.71	150	348	655	1424	2168	4182	8473	13154
73	0.73	152	354	665	1447	2200	4246	8600	13336
76	0.76	155	359	675	1465	2236	4305	8723	13563
77	0.77	157	365	685	1488	2268	4368	8850	13744
78	0.78	158	366	689	1497	2282	4390	8900	13812
80	0.8	160	370	695	1510	2300	4427	8972	13925
82	0.82	162	375	704	1529	2331	4491	9072	14407
88	0.88	168	391	733	1590	2427	4536	9453	14651
90	0.9	170	395	740	1606	2449	4717	9548	14787
98	0.98	179	414	777	1696	2567	4944	10025	15513
100	1	180	418	785	1701	2590	4990	10115	15649
114	1.14	194	450	845	1832	2790	5366	10841	16828
118	1.18	198	457	857	1860	2830	5443	11022	17055
120	1.2	199	462	867	1880	2860	5502	11113	17282
131	1.31	209	484	907	1969	2994	5761	11657	18053
137	1.37	215	497	931	2018	3071	5906	11948	18507
140	1.4	216	502	939	2037	3103	5965	12066	18688
147	1.47	224	516	966	2096	3189	6128	12383	19187
157	1.57	231	534	1002	2168	3298	6337	12814	19822
160	1.6	234	541	1011	2195	3340	6409	12973	20049
163	1.63	237	546	1025	2218	3370	6477	13109	20276
176	1.76	246	570	1066	2309	3511	6740	13608	21092
180	1.8	249	576	1075	2331	3547	6808	13744	21319
196	1.96	261	603	1129	2440	3710	7130	14379	22317
200	2	265	611	1143	2472	3760	7221	14560	22589
212	2.12	273	629	1179	2549	3874	7430	15014	23270
216	2.16	275	634	1188	2567	3905	7493	15132	23451
220	2.2	278	641	1200	2595	3942	7570	15277	23678
229	2.29	284	655	1225	2649	4028	7729	15604	24177
235	2.35	288	664	1243	2689	4086	7843	15840	24522
240	2.4	292	672	1256	2719	4129	7927	16017	24780
245	2.45	295	679	1270	2749	4173	8010	16193	25039
255	2.55	301	694	1297	2806	4260	8176	16520	25556
260	2.6	304	701	1311	2834	4304	8260	16683	25814
261	2.61	305	703	1315	2844	4318	8287	16738	25900
274	2.74	313	721	1348	2917	4331	8501	17173	26554
277	2.77	315	727	1356	2935	4459	8555	17282	26717
280	2.8	317	730	1363	2948	4479	8593	17357	26839
294	2.94	325	749	1402	3025	4595	8813	17781	27533
300	3	328	757	1414	3055	4641	8900	17956	27803
310	3.1	335	771	1438	3112	4726	9063	18280	28305
314	3.14	336	775	1446	3129	4752	9074	18380	28459
320	3.2	340	784	1462	3163	4825	9204	18579	28767
327	3.27	344	792	1479	3198	4853	9299	18779	29076
333	3.33	348	801	1495	3230	4904	9408	18979	29366
340	3.4	351	809	1511	3263	4955	9516	19178	29656
342	3.42	353	813	1520	3279	4980	9571	19278	29801
353	3.53	358	825	1541	3328	5054	9707	19550	30237
359	3.59	362	834	1556	3361	5103	9798	19732	30527
360	3.6	363	835	1558	3365	5109	9809	19754	30564
372	3.72	369	850	1585	3423	5201	9979	20094	31108
376	3.76	371	854	1592	3438	5225	10024	20185	31253
380	3.8	373	859	1601	3457	5254	10081	20299	31423
392	3.92	379	873	1628	3515	5339	10251	20639	31933
400	4	383	883	1646	3554	5398	10342	20866	32274
408	4.08	388	892	1665	3592	5457	10433	21092	32614
412	4.12	390	896	1672	3608	5479	10478	21174	32750
420	4.2	394	906	1690	3646	5536	10592	21378	33090
425	4.25	396	912	1701	3670	5570	10660	21500	33294

Design Notes

Maximum Condensate Flow: Achieved during plant start-up when pipes and equipment are heated up
Design Rule: The condensate load used to design condensate pipe lines should be twice the maximum production load
Units: SI Units (Pa/m, kg/h)

Equipment Piping and Condensate Load

Typical maximum condensate load and equipment outlet pipe size:

Maximum Condensate Load (kg/h)	Outlet Pipe Size (mm, in)
200	15 (1/2)
500	20 (3/4)
1000	25 (1)
2000	32 (1 1/4)
3000	40 (1 1/2)
5000	50 (2)
> 5000	65 - 100 (2 1/2 - 4)