Condensate Return

• Hotter boiler feed water temperatures

• Minimizes the amount of chemicals required to treat boiler feed
water
• Eliminates environmental concerns
• Minimizes water usage which is critical in some areas
• Condensate is a tangible item which can be measured in the
form of a savings analysis

2
 Condensate Recovery Savings

3
 Where Does Stall Occur?
• Air heating coils

• Shell & tube heat exchangers

• Plate & frame heat exchangers

• Absorption chillers

• Kettles

6
 Effects of Stall
Inadequate
condensate drainage

Poor temperature
Water hammer control of product

Frozen coils Effects of Control valve

Stall hunting
Corrosion due Reduction of heat
to Carbonic Acid transfer capacity

7
 Factors Contributing to Stall

Oversized High back

01 equipment 03 pressure

Large
02 operating Changes in
ranges 04 system
parameters

8
 What is the Stall Solution?

• Use a bigger steam trap?

• Use a vacuum breaker?

• Implement a safety drain trap?

9
 Methods of Condensate Return

10
 Float Switch Pointer

12
 Electric Pump Control Panel

13
 Cavitation
Discharge A. When impeller rotates a
Vanes
Impeller pressure drop is created at the
suction eye.

Suction B. Hot condensate can flash back

into steam during this drop in
Eye
pressure.
C. As the vanes sling the condensate
outward pressure is generated at
Pump the pump housing and the flashed
Housing steam collapses.

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 Electric Pumps
Advantages Disadvantages

01 04
Leaking
Low initial cost Repetitive
seals
Inexpensive maintenance
potential

02
05 High
Pumps mounted Low inlet
height Impeller temperature
to receiver
applications wear condensate

03 06
High flow rates Safety for pit
Footprint Safety
& discharge pressures areas (flooding)

16
 Mechanical Pumps

17
 Pump Trap Operation: Filling
Steam/Air In - Closed Steam/Air Out - Open

Open Inlet CV

Closed Outlet CV

Step 1. During filling, the steam / air inlet and outlet check valve are closed. The vent and inlet
check valve are open.

18
 Pump Trap Operation: Begin Pumping
Steam/Air In - Open Steam/Air Out - Closed

Closed Inlet CV

Open Outlet CV

Step 2. Float Rises with level of condensate until it passes trip point, and then snap action
reverses the positions shown in step one.

19
 Pump Trap Operation: End Pumping
Steam/Air In - Open Steam/Air Out - Closed

Closed Inlet CV

Open Outlet CV

Step 3. Float is lowered as level of condensate falls until snap action again reverses positions.

20
 Pump Trap Operation: Repeat Filling
Steam/Air In - Closed Steam/Air Out - Open

Open Inlet CV

Closed Outlet CV

Step 4. Steam / air inlet and pump outlet are re-closed while the vent and pump inlet are re-
opened.

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 Mechanical Electrical

Low maintenance Low initial cost

vs
Capable of Capable of
pumping hot pumping cooler
condensate condensate

No electrical Small footprint

requirements

22
 Mechanical Pump Installations
Open System Closed System

23
 Open
Loop
Pump
System
 Considerations for Open Systems

Receiver sizing
Receiver must be sized to provide Fill Head
adequate separation of flash Distance between receiver
steam and condensate and pump affects fill rate

Vent Sizing Flash Steam

Vent line velocity of 3,000 – Condensate must
4,000 FPM be allowed to flash
prior to entering the
pump

25
 Vented Receiver Sizing
Vented Receiver Sizing for Open Systems
Receiver Receiver Vent Line
Flash Steam
Diameter Length Diameter
lb/hr kg/hr in mm in mm in mm
up to
75 34 4 102 36 914 1-1/2 40
150 68 6 152 36 914 2 50
300 136 9 229 36 914 2-1/2 65
600 272 10 254 36 914 3 75
900 408 12 300 36 914 4 100
1200 544 16 405 36 914 6 150
2000 907 20 508 36 914 8 200

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 Open System Overview
Advantages: Precautions:
- Drain multiple pieces of - Overflow piping should be
equipment present
- Air or steam can be used - Receiver needs to be sized
as motive
properly
- No flash steam in return
lines

27
 Closed
Loop Pump
System
(Trapping)
 Closed
Loop Pump
System
(Pumping)
 Pump Trap for Closed Loop

38
 Considerations for Closed-Loop Systems

RECEIVER SIZING
Typically a smaller
receiver can be used to
handle condensate load
only

FILL HEAD OF RECEIVER

VENT SIZING ON RECEIVER Prevent flashing in
the pump trap
Vent line is equalized to receiver
and capped with thermostatic air
vent or A/VB combination

40
 Closed Loop Receiver Sizing
Inlet Reservoir Pipe Sizing for Closed Systems
Condensate Reservoir Pipe Diameter
Load in mm in mm in mm in mm in mm in mm
lb/hr 2 50 3 75 4 100 6 150 8 200 10 250
up to Length of Pipe
ft m ft m ft m ft m ft m ft m
500 227 4 1.2 2-1/2 0.7 1-1/2 0.4
1,000 453 4-1/2 1.4 2 0.6 1-1/2 0.4
1,500 680 7 2.1 3 0.9 2 0.6
2,000 907 9 2.7 4 1.2 2-1/2 0.7
2,500 1,134 11 3.4 5 1.5 3 0.9 1-3/4 0.5
3,000 1,360 13-1/2 4.1 6 1.8 3-1/3 1.1 2 0.6
4,000 1,814 18 5.5 8-1/2 2.6 5 1.5 2-1/2 0.7
5,000 2,268 10 3.0 6 1.8 3 0.9 1-1/2 0.4
6,000 2,722 12 3.7 7 2.1 3-1/2 1.1 2 0.6
7,000 3,175 14-1/2 4.4 8-1/2 2.6 4 1.2 2 0.6
8,000 3,629 16-1/2 5.0 9-1/2 2.9 4-1/2 1.4 2-1/2 0.7 1-1/2 0.4
9,000 4,082 11 3.4 5 1.5 3 0.9 2 0.6
10,000 4,536 12 3.7 5-1/2 1.7 3 0.9 2 0.6
11,000 4,990 13 4.0 6 1.8 3-1/2 1.1 2 0.6
12,000 5,443 14 4.3 6-1/2 2.0 4 1.2 2-1/2 0.7

41
 Closed System Overview
Advantages: Precautions:
- Dedicated pump for a single piece
- No flash steam loss of equipment
- No need to run long - Can not use air as motive force
expensive vent lines
- Return line size must be double
- Return condensate hotter checked

42