SURFACE CONDENSER THERMAL CALCULATION

PROJECT : XX
System of Units
Symbol Description of Parameters
Value SI Unit Value FPS Unit
LMTD CALCULATION OF SURFACE CONDENSER
T1 Cooling Water Inlet Temperature 31.00 deg. C 87.80 deg. F
T2 Cooling Water Outlet Temperature 35.00 deg. C 95.00 deg. F
TR Temperature Rise 4.00 deg. C 7.20 deg. F
TS Condenser Steam Inlet Temperature (from HMBD) 39.00 deg. C 102.20 deg. F
ITD Initial Temperature Difference = (TS - T1) 8.00 deg. C 14.40 deg. F
TTD Terminal Temperature Difference = (TS - T2) 4.00 deg. C 7.20 deg. F
LMTD Log Mean Temperature Difference = TR / Ln (ITD/TTD) 5.77 deg. C 10.39 deg. F

OVERALL HEAT TRANSFER COEFFICIENT "U" CALCULATION ON CLEANLINESS FACTOR

Condenser Tube Material Titanium
VW Velocity of water through condenser tubes 2.00 m/sec 6.56 ft/sec
U1 Uncorrected Heat Transfer Coefficient (From HEI) 13769.9721 kJ/m h.deg.C
2
673.6200 Btu/ft h.deg.F
2

FW Inlet Water Temperature Correction Factor (From HEI) 1.0684

FM Tube Material & Gauge Correction Factor (from HEI) 0.9200
FC Cleanliness Factor (as per HEI) 0.8500
U Overall Heat Transfer Coefficient = U1 x FW x FM x FC 11504.6575 kJ/m2h.deg.C 562.8020 Btu/ft2h.deg.F

SURFACE AREA CALCULATION OF SURFACE CONDENSER

Q Heat Load on Surface Condenser (Estimated from HMBD) 1434986084 kJ/hr 1360104349 Btu/hr
U Overall Heat Transfer Co-efficient 11504.6575 kJ/m2h.deg.C 562.8020 Btu/ft2h.deg.F
LMTD Log Mean Temperature Difference 5.77 deg. C 10.39 deg. F
A Total area required = Q / (U x LMTD) 21614.21 m2 232653.50 ft2

CALCULATION OF TUBE QUANTITY

D Tube Outside Diameter (selected) 25.40 mm 1 inch
td Tube thickness 0.635 mm 23 BWG
D1 Tube Inside Diameter 24.13 mm 0.9500 inch
L Length of Tubes considered 5220.65 mm 205.54 inch
A Total Area Required 21614.21 m2 232653.50 ft2
N No of Tubes Required = A / (D x L x π) 51884 Nos

COOLING WATER CALCULATION FOR SURFACE CONDENSER

Q Heat Load on Surface Condenser 1434986084 kJ/hr 1360104349 Btu/hr
SG Specific Gravity of CW 1.0
CP Specific Heat of CW 4.2 kJ/kg.deg. C 1.0 Btu/lb.deg. F
TR Cooling Water Temperature Rise 4.0 deg. C 7.20 deg. F
WG Water Flow (in GPM) = Q/(1000 x SG x CP x TR) 85415.84 m3/hr 376074.66 GPM

TUBE SIDE VELOCITY CALCULATION FOR SURFACE CONDENSER

N No of Tubes 51884 Nos
NP No of Tube Pass 2 Nos
AD1 Tube Inside Cross Sectional Area/Pass 11.86 m2 127.70 ft2
WG Water Flow calculated from Heat Load 85415.84 m /hr
3
376074.66 GPM
(VW)act Actual Velocity of water in Tubes = W G / AD1 2.000 m/sec 6.56 ft/sec
0.0000
Reference : Heat Exchange Institute Standards for Steam Surface Condensers - Ninth Edition.

]
 Tube Velocity UNCORRECTED HEAT TRANSFER CO-EFFICIENTS (U1) FOR TUBE OUTSIDE DIAMETER (INCHES)

(ft/sec) 0.625 0.75 0.875 1 1.125 1.25 1.375 1.5 1.625 1.75 1.875 2
2 3 4 5 6 7 8 9 10 11 12 13
3.0 462.5 462.5 455 455 448.6 448.6 441.7 441.7 434.7 434.7 427.8 427.8
3.0 3.5 499.5 499.5 492 492 484.5 484.5 477.1 477.1 469.6 469.6 462.1 462.1
3.5 4.0 534 534 526 526 518 518 510 510 502 502 494 494
4.0 4.5 566.4 566.4 557.9 557.9 549.4 549.4 540.9 540.9 532 532 524 524
4.5 5.0 597 597 588.1 588.1 579.1 579.1 570.2 570.2 561.3 561.3 552.3 552.3
5.0 5.5 626.2 626.2 616.8 616.8 607.4 607.4 598 598 588.6 588.6 579.8 579.8
5.5 6.0 654 654 644.2 644.2 634.4 634.4 624.6 624.6 614.8 614.8 605 605
6.0 6.5 680.7 680.7 670.5 670.5 660.3 660.3 650.1 650.1 639.9 639.9 629.7 629.7
6.5 7.0 706.4 706.4 695.8 695.8 685.2 685.2 674.7 674.7 664.1 664.1 653.5 653.5
7.0 7.5 731.2 731.2 720.3 720.3 709.3 709.3 698.3 698.3 687.4 687.4 676.4 676.4
7.5 8.0 755.2 755.2 743.9 743.9 732.6 732.6 721.2 721.2 709.9 709.9 698.6 698.6
8.0 8.5 775.5 775.5 763.9 763.9 752 752 740.4 740.4 727.8 727.8 716.8 716.8
8.5 9.0 795.3 795.3 783.2 783.2 770.7 770.7 758.7 758.7 745.7 745.7 734.4 734.4
9.0 9.5 814.1 814.1 801.6 801.6 788.4 788.4 776.1 776.1 762.7 762.7 751 751
9.5 10.0 831.9 831.9 819 819 805.3 805.3 792.6 792.6 778.8 778.8 766.8 766.8
10.0 10.5 848.9 848.9 835.6 835.6 821.4 821.4 808.3 808.3 794.1 794.1 781.8 781.8
10.5 11.0 865.2 865.2 851.5 851.5 836.7 836.7 823.2 823.2 808.8 808.8 796.2 796.2
11.0 11.5 880.7 880.7 866.6 866.6 851.3 851.3 837.5 837.5 822.7 822.7 809.8 809.8
11.5 12.0 895.6 895.6 881.1 881.1 865.3 865.3 851.2 851.2 836 836 822.9 822.9

Note : The above table has been taken from Page 7 (Table 1) of HEI Standards for Steam Surface Condensers - Ninth Edition.

Interpolation for Uncorrected Heat Transfer Co-efficient (U1) at given velocity of water

Actual velocity of water in tubes = 6.56 ft/sec

1st Tube Velocity (ft/sec) = 6.5 ft/sec 1st U1 = 670.5

2nd Tube Velocity (ft/sec) = 7 ft/sec 2nd U1 = 695.8

Actual U1 = 673.62 Btu/ft2h.deg.F

= 13769.97 kJ/m2h.deg.C
 INLET WATER TEMPERATURE CORRECTION FACTOR (FW)

Inlet Water
Temperature FW
(deg. F) Interpolation for Inlet Water Temperature Correction Factor (FW)
30 0.650
30 31 0.659 Actual Inlet Water Temperature = 87.80 deg. F
31 32 0.669
32 33 0.678 1st Temperature = 87 deg. F
33 34 0.687
34 35 0.696 2nd Temperature = 88 deg. F
35 36 0.706
36 37 0.715
37 38 0.724 1st FW = 1.066
38 39 0.733
39 40 0.743 2nd FW = 1.069 Actual FW = 1.068
40 41 0.752
41 42 0.761
42 43 0.770
43 44 0.780 NOTE : REFER TABLE-2 IN PAGE 9 OF HEI STD FOR STEAM SURFACE CONDENSERS - 9TH EDITION
44 45 0.789 FOR INLET WATER TEMPERATURE CORRECTION FACTOR.
45 46 0.798
46 47 0.807
47 48 0.816
48 49 0.825
49 50 0.834
50 51 0.843
51 52 0.852
52 53 0.861
53 54 0.870
54 55 0.879
55 56 0.888
56 57 0.897
57 58 0.905
58 59 0.914
59 60 0.923
60 61 0.932
 61 62 0.941
62 63 0.950
63 64 0.959
64 65 0.968
65 66 0.975
66 67 0.982
67 68 0.989
68 69 0.994
69 70 1.000
70 71 1.005
71 72 1.010
72 73 1.015
73 74 1.020
74 75 1.025
75 76 1.029
76 77 1.033
77 78 1.037
78 79 1.041
79 80 1.045
80 81 1.048
81 82 1.051
82 83 1.054
83 84 1.057
84 85 1.060
85 86 1.063
86 87 1.066
87 88 1.069
88 89 1.072
89 90 1.075
90 91 1.078
91 92 1.080
92 93 1.083
93 94 1.085
94 95 1.088
95 96 1.090
96 97 1.092
97 98 1.095
98 99 1.097
99 100 1.100
100 101 1.103
101 102 1.105
102 103 1.108
103 104 1.110
104 105 1.113
105 106 1.115
106 107 1.117
107 108 1.119
108 109 1.121
109 110 1.123
110 111 1.125
111 112 1.127
112 113 1.129
113 114 1.131
114 115 1.133
115 116 1.135
116 117 1.137
117 118 1.139
118 119 1.141
119 120 1.143
 Uncorrected Heat Transfer Co-efficient (U1)

950
925

U1 (Btu/ft2-hr-degF)
900
875
850
825
800
775
750
725
700
675 0.625" & 0.75" Tube OD
650 0.875" & 1.00" Tube OD
625
600 1.125" & 1.25" Tube OD
575
1.375" & 1.5" Tube OD
550
525 1.625" & 1.75" Tube OD
500
475 1.875" & 2.00" Tube OD
450
425
400
3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0
Vw (ft/sec)
 Inlet Water Temperature Correction Factor (Fw)

Correction Factor (Fw)

1.200
1.150
1.100
1.050
1.000
0.950
0.900
0.850
0.800
0.750
0.700
0.650
0.600
0.550
0.500
30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120
Inlet Water Temperature (deg. F)
TUBE MATERIAL AND GAUGE CORRECTION FACTOR (FM)

Tube Materials TUBE WALL GAUGE - BWG

12 14 16 18 20 22 23 24 25
70-30 Cu-Ni 0.71 0.78 0.83 0.88 0.92 0.95 0.96 0.97 0.97 2
90-10 Cu-Ni 0.80 0.85 0.89 0.93 0.96 0.98 0.99 0.99 1.00 3
Admiralty Metal 0.93 0.96 0.98 1.00 1.01 1.02 1.02 1.03 1.03 4
Aluminium Brass 0.92 0.95 0.97 0.99 1.01 1.02 1.02 1.02 1.03 5
Aluminium Bronze 0.89 0.93 0.96 0.98 1.00 1.01 1.01 1.02 1.02 6
Arsenical Copper 0.98 1.00 1.01 1.02 1.03 1.03 1.04 1.04 1.04 7
Cold Rolled CS 0.80 0.85 0.89 0.93 0.97 0.98 0.99 1.00 1.00 8
Copper Iron 194 1.00 1.01 1.02 1.03 1.03 1.04 1.04 1.04 1.04 9
SS 304 0.54 0.62 0.69 0.75 0.82 0.86 0.88 0.90 0.91 10
SS 316 0.54 0.62 0.69 0.75 0.82 0.86 0.88 0.90 0.91 11
Titanium 0.63 0.71 0.77 0.82 0.88 0.91 0.92 0.94 0.95 12
UNS N08367 0.52 0.60 0.67 0.74 0.81 0.85 0.87 0.89 0.90 13
UNS S43035 0.63 0.71 0.77 0.82 0.88 0.91 0.92 0.94 0.95 14
UNS S44660 0.57 0.65 0.72 0.78 0.85 0.88 0.90 0.91 0.93 15
UNS S44735 0.57 0.65 0.72 0.78 0.85 0.88 0.90 0.91 0.93 16
3 4 5 6 7 8 9 10 11 17

NOTE : THE ABOVE TABLE HAS BEEN TAKEN FROM TABLE 3 IN PAGE NO. 11 OF HEI STD FOR STEAM SURFACE
CONDENSERS - NINTH EDITION.
 Table for Tube Characteristics

TUBE CHARACTERISTICS

Inside Length in Feet for Water - GPM at

OD of Tubing Thickness Surface External Sq.
BWG Diameter 1 for 1 Sq. Ft. 1 Foot Per Sec
(Inches) (Inches) Ft. Per Linear Foot
(Inches) Surface Velocity

12 0.109 0.407 0.1636 6.112 0.406

13 0.095 0.435 0.1636 6.112 0.463
14 0.083 0.459 0.1636 6.112 0.516
15 0.072 0.481 0.1636 6.112 0.566
16 0.065 0.495 0.1636 6.112 0.600
17 0.058 0.509 0.1636 6.112 0.634
18 0.049 0.527 0.1636 6.112 0.680
5/8
19 0.042 0.541 0.1636 6.112 0.716
20 0.035 0.555 0.1636 6.112 0.754
21 0.032 0.561 0.1636 6.112 0.770
22 0.028 0.569 0.1636 6.112 0.793
23 0.025 0.575 0.1636 6.112 0.809
24 0.022 0.581 0.1636 6.112 0.826
25 0.020 0.585 0.1636 6.112 0.838
12 0.109 0.532 0.1963 5.094 0.693
13 0.095 0.560 0.1963 5.094 0.768
14 0.083 0.584 0.1963 5.094 0.835
15 0.072 0.606 0.1963 5.094 0.899
16 0.065 0.620 0.1963 5.094 0.941
17 0.058 0.634 0.1963 5.094 0.984
18 0.049 0.652 0.1963 5.094 1.041
3/4
19 0.042 0.666 0.1963 5.094 1.086
20 0.035 0.680 0.1963 5.094 1.132
21 0.032 0.686 0.1963 5.094 1.152
22 0.028 0.694 0.1963 5.094 1.179
23 0.025 0.700 0.1963 5.094 1.200
24 0.022 0.706 0.1963 5.094 1.220
25 0.020 0.710 0.1963 5.094 1.234
12 0.109 0.657 0.2291 4.367 1.057
13 0.095 0.685 0.2291 4.367 1.149
14 0.083 0.709 0.2291 4.367 1.231
15 0.072 0.731 0.2291 4.367 1.308
16 0.065 0.745 0.2291 4.367 1.359
17 0.058 0.759 0.2291 4.367 1.410
18 0.049 0.777 0.2291 4.367 1.478
7/8
19 0.042 0.791 0.2291 4.367 1.532
20 0.035 0.805 0.2291 4.367 1.586
21 0.032 0.811 0.2291 4.367 1.610
22 0.028 0.819 0.2291 4.367 1.642
23 0.025 0.825 0.2291 4.367 1.666
24 0.022 0.831 0.2291 4.367 1.690
25 0.020 0.835 0.2291 4.367 1.707
12 0.109 0.782 0.2618 3.817 1.497
13 0.095 0.810 0.2618 3.817 1.606
14 0.083 0.834 0.2618 3.817 1.703
15 0.072 0.856 0.2618 3.817 1.794
16 0.065 0.870 0.2618 3.817 1.853
17 0.058 0.884 0.2618 3.817 1.913
18 0.049 0.902 0.2618 3.817 1.992
1
19 0.042 0.916 0.2618 3.817 2.054
20 0.035 0.930 0.2618 3.817 2.117
21 0.032 0.936 0.2618 3.817 2.145
22 0.028 0.944 0.2618 3.817 2.182
23 0.025 0.950 0.2618 3.817 2.209
24 0.022 0.956 0.2618 3.817 2.237
25 0.020 0.960 0.2618 3.817 2.256
12 0.109 0.907 0.2944 3.397 2.014
13 0.095 0.935 0.2944 3.397 2.140
14 0.083 0.959 0.2944 3.397 2.251
15 0.072 0.981 0.2944 3.397 2.356
16 0.065 0.995 0.2944 3.397 2.424
17 0.058 1.009 0.2944 3.397 2.492
18 0.049 1.027 0.2944 3.397 2.582
1 1/8
19 0.042 1.041 0.2944 3.397 2.653

Page : 9
 Table for Tube Characteristics

Inside Length in Feet for Water - GPM at

OD of Tubing Thickness Surface External Sq.
BWG Diameter 1 for 1 Sq. Ft. 1 Foot Per Sec
(Inches) (Inches) Ft. Per Linear Foot
(Inches) Surface Velocity
1 1/8
20 0.035 1.055 0.2944 3.397 2.725
21 0.032 1.061 0.2944 3.397 2.756
22 0.028 1.069 0.2944 3.397 2.797
23 0.025 1.075 0.2944 3.397 2.829
24 0.022 1.081 0.2944 3.397 2.861
25 0.020 1.085 0.2944 3.397 2.882
12 0.109 1.032 0.3271 3.057 2.607
13 0.095 1.060 0.3271 3.057 2.751
14 0.083 1.084 0.3271 3.057 2.877
15 0.072 1.106 0.3271 3.057 2.994
16 0.065 1.120 0.3271 3.057 3.071
17 0.058 1.134 0.3271 3.057 3.148
18 0.049 1.152 0.3271 3.057 3.249
1 1/4
19 0.042 1.166 0.3271 3.057 3.328
20 0.035 1.180 0.3271 3.057 3.409
21 0.032 1.186 0.3271 3.057 3.443
22 0.028 1.194 0.3271 3.057 3.490
23 0.025 1.200 0.3271 3.057 3.525
24 0.022 1.206 0.3271 3.057 3.560
25 0.020 1.210 0.3271 3.057 3.584
12 0.109 1.157 0.3600 2.778 3.272
13 0.095 1.185 0.3600 2.778 3.433
14 0.083 1.209 0.3600 2.778 3.573
15 0.072 1.231 0.3600 2.778 3.705
16 0.065 1.245 0.3600 2.778 3.790
17 0.058 1.259 0.3600 2.778 3.876
18 0.049 1.277 0.3600 2.778 3.987
1 3/8
19 0.042 1.291 0.3600 2.778 4.075
20 0.035 1.305 0.3600 2.778 4.164
21 0.032 1.311 0.3600 2.778 4.202
22 0.028 1.319 0.3600 2.778 4.254
23 0.025 1.325 0.3600 2.778 4.292
24 0.022 1.331 0.3600 2.778 4.331
25 0.020 1.335 0.3600 2.778 4.363
12 0.109 1.282 0.3927 2.546 4.018
13 0.095 1.310 0.3927 2.546 4.196
14 0.083 1.334 0.3927 2.546 4.351
15 0.072 1.356 0.3927 2.546 4.496
16 0.065 1.370 0.3927 2.546 4.589
17 0.058 1.384 0.3927 2.546 4.683
18 0.049 1.402 0.3927 2.546 4.806
1 1/2
19 0.042 1.416 0.3927 2.546 4.902
20 0.035 1.430 0.3927 2.546 5.000
21 0.032 1.436 0.3927 2.546 5.042
22 0.028 1.444 0.3927 2.546 5.099
23 0.025 1.450 0.3927 2.546 5.141
24 0.022 1.456 0.3927 2.546 5.183
25 0.020 1.460 0.3927 2.546 5.218
12 0.109 1.407 0.4254 2.351 4.840
13 0.095 1.435 0.4254 2.351 5.035
14 0.083 1.459 0.4254 2.351 5.205
15 0.072 1.481 0.4254 2.351 5.363
16 0.065 1.495 0.4254 2.351 5.465
17 0.058 1.509 0.4254 2.351 5.567
18 0.049 1.527 0.4254 2.351 5.701
1 5/8
19 0.042 1.541 0.4254 2.351 5.806
20 0.035 1.555 0.4254 2.351 5.912
21 0.032 1.561 0.4254 2.351 5.958
22 0.028 1.569 0.4254 2.351 6.019
23 0.025 1.575 0.4254 2.351 6.065
24 0.022 1.581 0.4254 2.351 6.111
25 0.020 1.585 0.4254 2.351 6.150
12 0.109 1.532 0.4581 2.183 5.738
13 0.095 1.560 0.4581 2.183 5.950
14 0.083 1.584 0.4581 2.183 6.135
15 0.072 1.606 0.4581 2.183 6.306

Page : 10
1 3/4
 Table for Tube Characteristics

Inside Length in Feet for Water - GPM at

OD of Tubing Thickness Surface External Sq.
BWG Diameter 1 for 1 Sq. Ft. 1 Foot Per Sec
(Inches) (Inches) Ft. Per Linear Foot
(Inches) Surface Velocity

16 0.065 1.620 0.4581 2.183 6.417

17 0.058 1.634 0.4581 2.183 6.528
18 0.049 1.652 0.4581 2.183 6.673
1 3/4
19 0.042 1.666 0.4581 2.183 6.786
20 0.035 1.680 0.4581 2.183 6.901
21 0.032 1.686 0.4581 2.183 6.950
22 0.028 1.694 0.4581 2.183 7.016
23 0.025 1.700 0.4581 2.183 7.066
24 0.022 1.706 0.4581 2.183 7.116
25 0.020 1.710 0.4581 2.183 7.158
12 0.109 1.657 0.4909 2.037 6.713
13 0.095 1.685 0.4909 2.037 6.942
14 0.083 1.709 0.4909 2.037 7.141
15 0.072 1.731 0.4909 2.037 7.326
16 0.065 1.745 0.4909 2.037 7.445
17 0.058 1.759 0.4909 2.037 7.565
18 0.049 1.777 0.4909 2.037 7.721
1 7/8
19 0.042 1.791 0.4909 2.037 7.843
20 0.035 1.805 0.4909 2.037 7.966
21 0.032 1.811 0.4909 2.037 8.019
22 0.028 1.819 0.4909 2.037 8.090
23 0.025 1.825 0.4909 2.037 8.143
24 0.022 1.831 0.4909 2.037 8.197
25 0.020 1.835 0.4909 2.037 8.243
12 0.109 1.782 0.5236 1.910 7.764
13 0.095 1.810 0.5236 1.910 8.010
14 0.083 1.834 0.5236 1.910 8.224
15 0.072 1.856 0.5236 1.910 8.422
16 0.065 1.870 0.5236 1.910 8.550
17 0.058 1.884 0.5236 1.910 8.679
18 0.049 1.902 0.5236 1.910 8.845
2
19 0.042 1.916 0.5236 1.910 8.976
20 0.035 1.930 0.5236 1.910 9.107
21 0.032 1.936 0.5236 1.910 9.164
22 0.028 1.944 0.5236 1.910 9.240
23 0.025 1.950 0.5236 1.910 9.298
24 0.022 1.956 0.5236 1.910 9.354
25 0.020 1.960 0.5236 1.910 9.404

Note : The above table has been taken from Table-7 in Page 24 of Heat Exchange Institute Standards for Steam Surface
Condensers - 9th Edition.

Page : 11