Condensate Recovery Systems

Steam System Training 13-1

2003
Condensate Recovery Systems
Condensate
When steam transfers its heat in a process, heat exchanger, or heating coil, it reverts to a
liquid phase called condensate. Condensate is condensed steam, not water.
Condensate contains:
Water
Boiler treatment chemicals
Particulate
Most importantly energy


Condensate therefore, needs to be returned to the boiler to:
Improve energy efficiency
Reduce chemical cost
Reduce make-up water costs
Reduce sewer system disposal costs
Why Have Pumps?

In gravity type systems the condensate lines do not have the pressure to flow the
condensate back to the boiler operation; therefore there is a need to have a vented
condensate pumping system. Another common application is the main collection point in
the boiler operation, where there is a need to collect the condensate and pump the
condensate to the deaerator system. In low, medium and high pressure systems there is a
need for condensate pumps depending the on the design of the system.

Types of Pumping Systems:

Electric (on-off operation)
Electric (continuous flow operation)
Steam motive type pump (self actuating)
Condensate Recovery Systems



Steam System Training 13-2
2003
Air motive type pump (self actuating)
Electric type steam or air motive pump
Applications for Each Type

Electric (On-Off)
As the condensate level in the tank increases to a
certain level, contacts close in a float switch and start
the condensate pump. The pump operates, until the
condensate level decreases to a point that the float
switch contact opens and the pump stops. This
operation repeats as the water level rises and falls.
The pump is allowed to operate at a nearly constant
head-capacity point and not over the entire pump
curve as with continuous operation.

Condensate capacities of 8,000 lbs per hour or less
Single pump or dual pump
Gravity systems, low pressure or medium pressure return system
Advantages:

o Low cost
o Simple operation

Disadvantages:

o Low capacities
o Surging in the condensate lines during pumping mode

Electric (Continuous Flow)
The condensate level is controlled by a modulating valve, which regulates to keep a
constant condensate level in the tank. As the demand increases and the level start to
increase, the valve opens further to let more condensate flow though the valve into the
condensate return system. As the demand decreases and the level begins to drop; the
valve closes down and reduces the amount of condensate being discharged.
Condensate Recovery Systems



Steam System Training 13-3
2003
The condensate pump operates continuously and
pumps against the modulating valve. The flow
corresponds to the pump performance curve at
various discharge heads relating to settings of the
modulating valve.
Continuous operation is more suited to centrifugal
pump operation, which allows for wide capacity
changes over a smaller change head pressure. Also,
the horsepower does not increase as a pump is
operating against a nearly closed modulating valve,
which can occur during operation.

Condensate capacities above 8,000 lbs per hour (high capacities)
Single pump operation (most common)
Gravity systems, low pressure or medium pressure return system
Advantages:

High capacities
Handles load variations

Continuous flow of condensate in the return system, therefore no
surging in the condensate lines

Disadvantages:

More complicated
Higher initial cost

Steam Motive Pump (Self Actuating)

The operating force of this type of pump is steam,
and the consumption is very low. Since the pump
handles a low volume of condensate at each stroke,
its applications are somewhat limited.
The steam-powered pumps can be used in a closed
loop system or a vented system to atmosphere. In a
closed loop system, a steam trap must be installed at
the discharge of the pump unit.
Condensate Recovery Systems



Steam System Training 13-4
2003
A vented receiver or collection header is an essential part of the installation, as any flash
steam must be separated from the condensate before it reaches the pump assembly.

Condensate capacities of 8,000 lbs per hour or less
Gravity systems, low pressure or medium pressure return system
o Advantages:
Low cost
Simple operation
No electric is required
Used in explosion proof areas
o Disadvantages:
Low capacities
Needs a fill head
Mechanical failures of the mechanism
Venting on flash steam in the chamber is limited

Air Motive Pump (Self Actuating)

The operating force of this type of pump is
compressed air, and the consumption is very low.
Since the pump handles a low volume of
condensate at each stroke, its applications are
somewhat limited.
It is not recommended that these types of pumps be
used in groups to handle larger condensate loads.

Condensate capacities of 8,000 lbs per hour or less
Gravity systems, low pressure or medium pressure return system
Advantages:
CONDENSATE PUMPS
Condensate Recovery Systems



Steam System Training 13-5
2003
Low cost
Simple operation
No electric is required
Used in explosion proof areas

Disadvantages:
Uses compressed air, which is typically a higher cost utility
Low capacities
Needs a fill head
Mechanical failures of the mechanism
Venting on flash steam in the chamber is limited








Condensate Recovery Systems



Steam System Training 13-6
2003
Electrical Steam or Air Motive Type Pump

The operating force of this type of pump is steam or compressed air. This type of unit
uses electrical level sensors to activate the steam or compressed air motive force.

Condensate capacities of 8,000 lbs per hour or less
Gravity systems, low pressure or medium pressure return system
Advantages:

No electrical pump
Disadvantages:

More complex than all other designs
Low capacities
Needs a fill head
Condensate Recovery Systems



Steam System Training 13-7
2003
Selecting the Correct Pumping System
Capacity required
Maximum
Minimum
Normal
Tank sizing
Required discharge pressure
NPSH required due to the temperature of the condensate
Control of the flow of condensate
Flash and neglect steam venting
Location and installation
Capacity Required
The plant needs to document the required capacity of the condensate pumping system.
Condensate pumps are used in a variety of process and heating applications. The
maximum load is never usually achieved and there is typically a great variance between
the normal high condensate flow and the minimum condensate flow. Therefore, careful
consideration must be given when defining the condensate capacity.
Sizing of Receivers
The receiver should be sized for capacity sufficient to allow condensate storage for a
minimum of 15 minutes.
Example:
Given condensate load:
4,000 lbs. per hour
4,000 div by 8.3 div by 60 =8.03 gpm
8.03 gpm x 15 =120 gallon storage tank
The tank material is typically a heavy wall steel tank or a stainless steel. In some cases,
the tank is coated with a corrosion-resistive material.

It is recommended that the tank be stamped ASME, even if the tank is vented to
atmosphere, to provide a more desirable tank construction for industrial applications.
Condensate Recovery Systems



Steam System Training 13-8
2003
NPSH
What Causes Cavitation
As liquid enters the eye of the impeller in a centrifugal pump, its pressure is reduced. If
the absolute pressure at the impeller eye drops down to the vapor pressure of the fluid,
vapor pockets begin to form. As these vapor pockets travel in the fluid along the vanes of
the impeller, pressure increases and the pockets collapse.
This collapse is called cavitation.
Cavitation is not only noisy but also damages the pump impeller, shaft and seal, and, over
time, may reduce pumping capacity. NPSH refers to the minimum suction pressure,
expressed in feet of water column, that is required to prevent the forming and collapsing
of these vapor pockets.
The diagram shows the change in system pressure (P
s
) as
the fluid travels through the impeller. To prevent
cavitation, P
s
must remain above the vapor pressure.
The top curve shows system pressure (P
s
) remaining
above fluid vapor pressure as it passes through the
pumps; cavitation cannot occur. The bottom curve shows
P
s
falling below the vapor pressure as it enters the
impeller eye. This will cause cavitation. The cutaway
view of a pump on the right shows the passage of flow
through the impeller.
Net Positive Suction Head (NPSH)
A critical factor that should be investigated in the
selection of a condensate pump is the NPSH due to the
high temperatures that do occur in condensate returns.
NPSH is determined by factors:
Temperature
Altitude
Static head
Capacity
NPSH = Barometric Pressure, Ft. +Static Head on
suction,ft. - friction losses in suction piping, ft. - Vapor
Pressure of liquid, ft.
Defined as a suction pressure minus vapor
pressure expressed in feet of liquid at the pump
suction. Results from the height of water above
the pump suction.
Suction Head =Total Pressure of Liquid Entering the Pump Suction
Condensate Recovery Systems



Steam System Training 13-9
2003
Two Values of NPSH
There are two values of NPSH: NPSHR and NPSHA.
NPSHR (required) is the amount of suction head required to prevent pump cavitation, is
determined by the pump design, and is indicated on the pump curve. It varies between
different makes of pumps, between different pumps of the same design and varies with
the capacity and speed of any one pump. This is a value that must be supplied by the
maker of the pump.
NPSHA (available) is the amount of suction head available or total useful energy above
the vapor pressure at the pump suction. This is determined by the system conditions.
NPSH typically is measured in ft of liquid.
Pounds Pressure versus Feet of Head
Each pound of pressure developed by a pumping system is equal to 2.31 feet of head.
Therefore, 10 pounds of pressure (PSI) will lift water vertically 23.1 feet.
This can be calculated for any setting using the following formula:
Pounds per sq. in. =Head in Feet
2.31
Head in Feet =Pounds per sq. in. x 2.31
TABLE 1NPSHA (at sea level) at various temperatures.
Temp., F. Vapor pressure of
water, psia
Vapor pressure of
water, ft
Positive head, ft
220 17.186 39.7 0
218 16.533 38.2 0
216 15.901 36.7 0
214 15.289 35.3 0
212 14.696 33.95 0
210 14.123 32.6 1.35
208 13.568 31.3 2.65
206 13.031 30.1 3.85
204 12.512 28.9 5.05
202 12.011 27.7 6.25
200 11.526 26.6 7.35
Condensate Recovery Systems



Steam System Training 13-10
2003
(Note: Water Temperature Rating) (Warning)

One of the most common pump systems is the floor
mounted horizontal tank with one or more pumps
mounted to the side of the tank. It must be understood
that this design is usually operated at temperatures below
205 degrees F. If temperature is higher the pumps will
cavitate and malfunction.

Another type of electric pump system is one with
the tank elevated above the pumps. This
arrangement provides the necessary NPSH for the
pumps, thus relieving a lot of the problems with
high condensate temperatures. This design is able
to operate with higher condensate temperatures
and is the preferred way of pumping condensate.

Intermittent (On/Off) VS Continuous
Operation
When designing condensate return pump systems there
are two ways to operate the pumps, on/off and
continuous flow.

8,000 lbs or less On-Off operation
8,001 lbs or more Continuous flow
To select flow rate for condensate pumps (on-off), multiply the required flow by 3 to
determine pumping capacity of a pump operating 1/3 of the time.
Example:
Given condensate rate = 4000 pounds per hour
Pumping rate (GPM) 4000 Lbs. /Hr.
8.33 x 3
60
= 24.1 GPM
Select a pump for approximately 24 GPM
Condensate Recovery Systems



Steam System Training 13-11
2003
VENT - RECEIVERS
Continuous flow should have a by-pass orifice or recirculation valve. These devices will
recirculate a required flow back to the receiver, if the control valve on the discharge side
of the pump closes to prevent the possibility of pumps overheating or cavitating.
Minimum By-Pass Sizing --Consult your pump manufacturer for assistance.


Shown here is a condensate pumping system with
continuous operation using a modulating control
valve at the discharge side of the pump.


Vent Sizing for Condensate Tanks

The vent for the condensate tank should be sized for the amount of flash steam. Please
refer to the flash steam tables in the first chapter. Also, the vent must have added
capacity for live steam that may occur from a poorly managed steam system.








The vent should be a lazy discharge of vapors without any velocities.



The most common failure of a condensate pump
system is the failure to size the vent properly. If
the vent is under sized, the tank will pressurize.
Condensate Recovery Systems



Steam System Training 13-12
2003
Vent Sizing
Example:
Load: 20,000 lbs per hour
System: 100 psig modulating
Tank: Vented to atmosphere
Flash %: 13.3
Flash load: 2,660 lbs per hour
Neglect factor: 40 steam traps
20% will be failed
8 steam traps at 500 lbs per hour each
4000 lbs per hour of neglect steam
(size vent to handle 6,660 lbs per hour of
steam to atmosphere at low velocities)
Energy Loss of the Vent
The energy loss from allowing the flash and neglect to go to atmosphere can be
calculated at:
Steam loss: 6,660 lbs per hour
Cost of steam: $5.00 per thousand lbs of steam
Hourly dollar loss: $33.00
Daily dollar loss: $792.00
Yearly dollar loss: $ 277,200.00










Condensate Recovery Systems



Steam System Training 13-13
2003


Condensate Recovery Systems



Steam System Training 13-14
2003