Instruction Manual -

Type 798 – Direct Contact

Spray Condenser

LAYOUT AND INSTALLATION

Clearances: Sufficient space must be provided around the unit for maintenance. Sufficient space must also
exist at the spray nozzle mounting port so the nozzle and nozzle holder can be removed.
The minimum recommended clearance is 1.5 times the length of the nozzle holder.
Cleanliness: Before installing, inspect all openings for foreign matter.
Setting & alignment: The Condenser should be installed vertically and should be plumb.
Piping: Pipe size should be selected after consideration of the entire system. The condenser connections
are sized on entrance considerations and are not necessarily suitable or required for the rest of
the system. Piping should be properly aligned and supported and adequate provision made for
thermal expansion. Condensate piping from condensers and steam heated units should be run
and pitched to assure complete drainage of the vapor space.
Vents and Drains: Proper venting is essential to the operation of any condenser and adequate drainage can be
important for corrosion control. Both are preferably run to atmosphere if the fluid involved permit,
otherwise they should run to areas of lower pressure with no pockets or obstructions to restrict
flow. Always drain a unit completely when it is to be shut down under freezing conditions.

Figure 1 - Tail Pipe Arrangement Figure 2 - Hotwell Design

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OPERATION
Before starting up, the system should be checked for correct piping and proper control and safety devices.
Application: Direct contact condensers can be used similarly to surface condensers in multi-stage steam jet systems
as pre-condensers, inter-condensers, and after-condensers to reduce the load to subsequent stages or
minimize emission of undesirable components. Direct contact condensers can be used in high fouling
services for which surface condensers may be unsuitable, and are used in applications where it is not
important to separate the condensate from the cooling water.

Operation: The EST type 798 direct Contact Spray Condenser uses cooling water to condense steam or other
condensable vapor. The water enters the condenser under pressure through a spray nozzle mounted at
the top of the condenser. The spray nozzle breaks the cooling water into a fine spray which provides a
large contact area with the gas. The gas enters the condenser and passes up through the water spray.
The counter current flow pattern allows the gas temperature to closely approach the inlet cooling water
temperature to maximize condensation of the condensable gas. The gas exits the condenser to the next
stage in the process. The heated cooling water is discharged through a barometric leg to a hot well.
Condenser
Theory: The operation of any condenser is described by a simple heat balance. The heat added up to the system
is the quantity of steam being condensed, expressed in pounds per hours, multiplied by the latent heat
of vaporization expressed in BTU per pound. This must be equal to the heat removed by the condensing
water which is the quantity of water expressed in pounds per hour multiplied by the temperature rise
from inlet to outlet times the specific heat (which is 1.0 in the case of water). It is apparent, therefore,
that the larger the temperature rise of the condensing water, the smaller the amount of water required.
Under theoretically perfect conditions, a condenser could be operated under a vacuum corresponding
to its tail and discharge water temperature, but no higher. Therefore, if water enters at 90°F and took a
10°F rise, the theoretical condenser pressure would be 1.933 inches Hg abs (vapor pressure of water at
100°F). Under normal operation this, of course, can never occur. Air entering with the injection water and
non-condensables entering with the vapor load exert a partial pressure. Ultimate condenser pressure is
the sum of the vapor pressure at the tail temperature, plus the partial pressure of the non-condensables
present. The difference between the temperature of the tail water and the temperature corresponding
to saturated water vapor at the actual condenser pressure is known as the "terminal difference". It is a
measure of efficiency of condenser operation.

The counter-current Barometric Condenser can operate with terminal differences of 3 to 5°F between
tail water and vapor dew point temperature. Large condensers will cool the non-condensables to within
5°F of the inlet water temperature. In cases where large percentages of non-condensables are present,
however, terminal differences as high as 30°F to 50°F may be expected since the condenser is actu-
ally performing as a gas cooler. This is particularly true where counter-current condensers are used as
intercondensers for multi-stage steam jet vacuum pumps (see EST Bulletin 700). There are no moving
parts in the Counter-Current Condenser. Also, little maintenance is required and provision can be made
for internal inspection of the unit. Because of the barometric leg, no water removal pump is required.
Due to efficient cooling of non-condensables, the supporting vacuum pump requires a minimum of live
steam for efficient operation.
Start-up
and Operation: The following procedure is generally applicable to all direct contact condensers:
1. Start the cooling water flow.
2. Gradually start the process gas, allowing the condenser to adjust its temperature slowly. Operate
the vents as required.
3. When shutting down, stop the process gas first, then operate the vents as required.
4. Avoid thermal shock due to rapidly altering the flow of either stream, unless the unit is specifically
designed to withstand this type of service.
5. Be sure all condensate is drained from the steam units before admitting steam to avoid water ham-
mer.
6. When the condenser has reached operating conditions, check all bolted connections for tightness.
7. Record operating pressures and temperature for future reference.

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INSPECTION AND MAINTENANCE
General Inspection
And Maintenance: 1. Inspection frequency depends on the aggressive nature of the service. Inspect as frequently as
neighboring equipment.
2. Use new replacement gaskets at flanged connections whenever reassembling condensers
after visual inspections. Remember that a vacuum system will show no exterior signs of
system leaks.
3. Keep a running log of the condenser performance including the inlet water temperature
and pressure. The relative tail-pipe vapor inlet temperature should be noticeably hotter
than the .water inlet.
4. Check the vapor out let temperature against the water inlet. The vapor outlet should
range from 5 to 20 degrees F above the water inlet temperature.
5. Condenser circumference should be checked at different horizontal levels for variations
in temperature at any point along a band. Many inspections can be conducted by touch
without instrumentation. Be careful.
6. Periodically check for spray nozzle wear.
7. Consult the TROUBLE SHOOTING instructions for the condenser and auxi1iary equipment
when poor operational symptoms arise.
Routine
Inspection: Condensers should be inspected periodically for corrosion. Check for corrosion, particularly around
connections and under insulation.
Temperature
Shocks: Condensers normally should not be subjected to abrupt temperature fluctuations. Hot fluid must not
be suddenly introduced when the unit is cold, nor cold fluid suddenly introduced when the unit is hot.
Cleaning: The method of cleaning will be indicated by the composition of the dirt or scale, its location and the
type of condenser. Each cleaning job must be considered individually with the help of cleaning tool
manufactures and chemical cleaning contractors.
Generally, the condenser can be cleaned mechanically. Mechanical cleaning tools must be applied
carefully to avoid damaging the spray nozzle and vessel shell. Sharp, hard cleaning tools should be
avoided. Chemical cleaning solutions must be used with care and completely flushed out to avoid cor-
rosion damage. Never use cleaning solutions containing hydrochloric acid on galvanized equipment.
Bolted Joints: Condensers are pressure tested before leaving the manufacturer's shop in accordance with ASME
Code requirements. However, normal relaxing of the gasketed joints may occur in the interval between
testing in the manufacturer's shop and installation at the jobsite. Therefore, all external bolted joints
may require retightening after installation and, if necessary, after the condenser has reached operating
temperature.
Reassembly
and Testing: Clean all gasket faces and use new gaskets of the same material, thickness and dimensions as
originally supplied. Pull up bolts only enough to produce a tight seal, alternating between diametrically
opposed bolts to keep flange faces parallel. Do not overstress bolts or flanges. When replacing bolts,
be sure to use the same alloy and grade as originally supplied.
Condensers are usually tested for tightness with water. Do
not pressurize with gas until it has been tested up to the
gas pressure with a liquid. Do not exceed the test pres-
sure on the nameplate of the Condenser.
Be careful to protect instruments and fixtures which are
not designed for the test pressure.
Recommended
Bolt Tightening
Procedure: It is important that all bolted joints be tightened uniformly
and in a diametrically staggered pattern, as illustrated in
the figure below, except for special high pressure closures
when the instructions of the manufacturer should be fol-
lowed.

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These instructions describe the installation, operation and maintenance of the subject equipment. Failure to strictly
follow these instructions can lead to equipment rupture that may cause significant property damage, severe personal
injury and even death. If you do not understand these instructions, please call Severn Trent Water Purification for
clarification before commencing any work at 215-997-4000 and ask for a Field Service Manager. Severn Trent
Water Purification, Inc. reserves the rights to make engineering refinements that may not be described herein. It
is the responsibility of the installer to contact Severn Trent Water Purification, Inc. for information that cannot be
answered specifically by these instructions.

Any customer request to alter or reduce the design safeguards incorporated into Severn Trent Water Purification
equipment is conditioned on the customer absolving Severn Trent Water Purification from any consequences of
such a decision.

Severn Trent Water Purification has developed the recommended installation, operating and maintenance procedures
with careful attention to safety. In addition to instruction/operating manuals, all instructions given on labels or attached
tags should be followed. Regardless of these efforts, it is not possible to eliminate all hazards from the equipment or
foresee every possible hazard that may occur. It is the responsibility of the installer to ensure that the recommended
installation instructions are followed. It is the responsibility of the user to ensure that the recommended operating
and maintenance instructions are followed. Severn Trent Water Purification, Inc. cannot be responsible deviations
from the recommended instructions that may result in a hazardous or unsafe condition.

Severn Trent Water Purification, Inc. cannot be responsible for the overall system design of which our equipment
may be an integral part of or any unauthorized modifications to the equipment made by any party other that Severn
Trent Water Purification, Inc.

Severn Trent Water Purification, Inc. takes all reasonable precautions in packaging the equipment to prevent shipping
damage. Carefully inspect each item and report damages immediately to the shipping agent involved for equipment
shipped “F.O.B. Colmar” or to Severn Trent Water Purification for equipment shipped “F.O.B Jobsite”. Do not install
damaged equipment.

SEVERN TRENT SERVICES, COLMAR OPERATIONS

COLMAR, PENNSYLVANIA, USA
IS ISO 9001: 2000 CERTIFIED

Design improvements may be made without notice.

Represented by:

Severn Trent Services

3000 Advance Lane Colmar, PA 18915
Tel: 215-997-4000 • Fax: 215-997-4062
Web: www.severntrentservices.com
E-mail: marketing@severntrentservices.com

NOV/08 Copyright 2008 Severn Trent Services

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