SpiraxSarco-B14-Condensate Recovery

Block 14 Condensate Recovery Introduction to Condensate Recovery Module 14.
Module 14.1
Introduction to
Condensate Recovery
The Steam and Condensate Loop 14.1.1

Block 14 Condensate Recovery Introduction to Condensate Recovery Module 14.1
Introduction to Condensate Recovery

Steam is usually generated for one of two reasons:
o To produce electrical power, for example in power stations or co-generation plants.
o To supply heat for heating and process systems.
When a kilogram of steam condenses completely, a kilogram of condensate is formed at the
same pressure and temperature (Figure 14.1.1). An efficient steam system will reuse this
condensate. Failure to reclaim and reuse condensate makes no financial, technical or
environmental sense.
1 kg steam Condensate 1 kg condensate
Fig. 14.1.1 1 kg of steam condenses completely to 1 kg of condensate
Saturated steam used for heating gives up its latent heat (enthalpy of evaporation), which is a
large proportion of the total heat it contains. The remainder of the heat in the steam is retained
in the condensate as sensible heat (enthalpy of water) (Figure 14.1.2).
Total heat
Latent heat
Steam used in
heating the
process Sensible heat
Condensate
Fig. 14.1.2 After giving up its latent heat to heat the process, steam turns to water containing only sensible heat
As well as having heat content, the condensate is basically distilled water, which is ideal for use
as boiler feedwater. An efficient steam system will collect this condensate and either return it to
a deaerator, a boiler feedtank, or use it in another process. Only when there is a real risk of
contamination should condensate not be returned to the boiler. Even then, it may be possible to
collect the condensate and use it as hot process water or pass it through a heat exchanger where
its heat content can be recovered before discharging the water mass to drain.
Condensate is discharged from steam plant and equipment through steam traps from a higher to
a lower pressure. As a result of this drop in pressure, some of the condensate will re-evaporate
into flash steam. The proportion of steam that will flash off in this way is determined by the
amount of heat that can be held in the steam and condensate. A flash steam amount of 10% to
15% by mass is typical (see Module 2.2). However, the percentage volumetric change can be
considerably more. Condensate at 7 bar g will lose about 13% of its mass when flashing to
atmospheric pressure, but the steam produced will require a space some 200 times larger than
the condensate from which it was formed. This can have the effect of choking undersized trap
discharge lines, and must be taken into account when sizing these lines.
14.1.2 The Steam and Condensate Loop

Example 14.1.1 Calculating the amount of flash steam from condensate

Hot condensate at 7 bar g has a heat content of about 721 kJ / kg. When it is released to atmospheric
pressure (0 bar g), each kilogram of water can only retain about 419 kJ of heat. The excess
energy in each kilogram of the condensate is therefore 721 419 = 302 kJ. This excess energy
is available to evaporate some of the condensate into steam, the amount evaporated being
determined by the proportion of excess heat to the amount of heat required to evaporate water
at the lower pressure, which in this example, is the enthalpy of evaporation at atmospheric
pressure, 2 258 kJ / kg.

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The subject of flash steam is examined in greater depth in Module 2.2, What is steam? A simple
graph (Figure 14.1.3) is used in this Module to calculate the proportion of flash steam.
Example:
Proportion of flash steam using Figure 14.1.3:
Pressure on the trap = 4 bar g
Flash steam pressure = 0 bar g
% Flash steam = 10%
The amount of flash steam in the pipe is the most important factor when sizing trap discharge lines.
Flash steam pressure bar g
15
14
ar g
ar g
ar g
ar g
ar g
rg
13
0 ba
2.0 b
2 .5 b
0.5 b
1.0 b
1.5 b
12
11
10
9
Pressure on traps bar
4
Atmospheric pressure
3
0
0 0.02 0.06 0.10 0.14 0.18 0.22
10%
kg Flash steam/kg condensate
Fig. 14.1.3 Quantity of Flash Steam Graph

Steam produced in a boiler by the process of adding heat to the water is often referred to as live
steam. The terms live steam and flash steam are only used to differentiate their origin. Whether
steam is produced in a boiler or from the natural process of flashing, it has exactly the same
potential for giving up heat, and each is used successfully for this purpose. The flash steam
generated from condensate can contain up to half of the total energy of the condensate. An
efficient steam system will recover and use flash steam. Condensate and flash steam discharged
to waste means more make-up water, more fuel, and increased running costs.
This Module will look at two essential areas condensate management and flash steam recovery.
Some of the apparent problem areas will be outlined and practical solutions proposed.
Note: The term trap is used to denote a steam-trapping device, which could be a steam trap, a
pump-trap, or a pump and trap combination. The ability of any trap to pass condensate relies
upon the pressure difference across it, whereas a pumping trap or a pump-trap combination will
be able to pass condensate irrespective of operational pressure differences (subject to design
pressure ratings).
Condensate return
An effective condensate recovery system, collecting the hot condensate from the steam using
equipment and returning it to the boiler feed system, can pay for itself in a remarkably short
period of time. Figure 14.1.4 shows a simple steam and condensate circuit, with condensate
returning to the boiler feedtank.
Pan Pan Space

heating
Process system
vessels
Steam
Steam
Condensate
Make-up
water
Vat Vat
Condensate
Steam
Feedtank
Boiler
Feedpump
Fig. 14.1.4 A typical steam and condensate circuit
Why return condensate and reuse it?

Financial reasons
Condensate is a valuable resource and even the recovery of small quantities is often economically
justifiable. The discharge from a single steam trap is often worth recovering.
Un-recovered condensate must be replaced in the boiler house by cold make-up water with
additional costs of water treatment and fuel to heat the water from a lower temperature.
Water charges
Any condensate not returned needs to be replaced by make-up water, incurring further water
charges from the local water supplier.

Effluent restrictions
In the UK for example, water above 43°C cannot be returned to the public sewer by law, because
it is detrimental to the environment and may damage earthenware pipes. Condensate above this
temperature must be cooled before it is discharged, which may incur extra energy costs. Similar
restrictions apply in most countries, and effluent charges and fines may be imposed by water
suppliers for non-compliance.
Maximising boiler output
Colder boiler feedwater will reduce the steaming rate of the boiler. The lower the feedwater
temperature, the more heat, and thus fuel needed to heat the water, thereby leaving less heat to
raise steam.
Boiler feedwater quality
Condensate is distilled water, which contains almost no total dissolved solids (TDS). Boilers need
to be blown down to reduce their concentration of dissolved solids in the boiler water. Returning
more condensate to the feedtank reduces the need for blowdown and thus reduces the energy
lost from the boiler.
Summary of reasons for condensate recovery:
o Water charges are reduced.
o Effluent charges and possible cooling costs are reduced.
o Fuel costs are reduced.
o More steam can be produced from the boiler.
o Boiler blowdown is reduced - less energy is lost from the boiler.
o Chemical treatment of raw make-up water is reduced.
Figure 14.1.5 compares the amount of energy in a kilogram of steam and condensate at the
same pressure. The percentage of energy in condensate to that in steam can vary from 18% at
1 bar g to 30% at 14 bar g; clearly the liquid condensate is worth reclaiming.
3000
Total energy in steam
Specific enthalpy (kJ / kg)
2500
2000
1500
1000
Total energy in
500 condensate
0
0 2 4 6 8 10 12 14
Pressure bar g
Fig. 14.1.5 Heat content of steam and condensate at the same pressures
The following example (Example 14.1.2) demonstrates the financial value of returning condensate.
Example 14.1.2
A boiler produces:
10 000 kg /h of steam 24 hours /day, 7 days/week and 50 weeks/year (8 400 hours / year).
Raw make-up water is at 10°C. Currently all condensate is discharged to waste at 90°C.
Raw water costs £0.61 / m3, and effluent costs are £0.45 / m3
The boiler is 85% efficient, and uses gas on an interruptible tariff charged at £0.01 / kWh (£2.77/GJ).

Determine the annual value of returning the condensate

Part 1 - Determine the fuel cost
Each kilogram of condensate not returned to the boiler feedtank must be replaced by 1 kg of
cold make-up water (10°C) that must be heated to the condensate temperature of 90°C.
(DT = 80°C).
Calculate the heat required to increase the temperature of 1 kg of cold make-up water by 80°C,
by using Equation 2.1.4.
4 PFS ∆7 Equation 2.1.4
Where:
Q = Quantity of energy (kJ)
m = Mass of the substance (kg)
cp = Specific heat capacity of the substance (kJ /kg °C )
DT = Temperature rise of the substance (°C)
m is unity; DT is the difference between the cold water make-up and the temperature of returned
condensate; cp is the specific heat of water at 4.19 kJ / kg °C.
1 kg x 4.19 kJ / kg °C x 80°C = 335 kJ / kg
Basing the calculations on an average evaporation rate of 10 000 kg / h, for a plant in operation
8 400 h / year, the energy required to replace the heat in the make-up water is:
10 000 kg / h x 335 kJ / kg x 8 400 h / year = 28 140 GJ / year
If the average boiler efficiency is 85%, the energy supplied to heat the make-up water is:
*- \HDU
*- \HDU

With a fuel cost of £2.77 / GJ, the value of the energy in the condensate is:
Annual fuel cost = 33 106 GJ / year x £2.77 / GJ = £91 704
Part 2 - Determine the water cost

Water is sold by volume, and the density of water at normal ambient temperature is about
1 000 kg / m3. The total amount of water required in one year replacing non-returned condensate
is therefore:
K[NJ K
Pó \HDU
NJ Pó
If water costs are £0.61 per m³, the annual water cost is:
Annual water cost = 84 000 m3 / year x £0.61 / m3 = £51 240
Part 3 - Determine the effluent cost

The condensate that was not recovered would have to be discharged to waste, and may also be
charged by the water authority.
Total amount of water to waste in one year also equals 84 000 m³
If effluent costs are £0.45 per m³, the annual effluent cost is:
Annual effluent cost = 84 000 m3 / year x £0.45 / m3 = £37 800

Part 4 - Total value of condensate

The total annual value of 10 000 kg / h of condensate lost to waste is shown in Table 14.1.1:
Table 14.1.1 The potential value of returning condensate in Example 14.1.2
Fuel savings = £ 91 704
Water savings = £ 51 240
Effluent savings = £ 37 800
Total value = £ 180 744
On this basis, it follows that for each 1% of condensate returned per 10 000 kg / h evaporated as
in Example 14.1.2, a saving of 1% of each of the values shown in Table 14.1.1 would be possible.
Example 14.1.3
If it were decided to invest £50 000 in a project to return 80% of the condensate in a similar
plant to Example 14.1.2, but where the total evaporation rate were only 5 000 kg / h, the savings
and simple payback term would be:

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6DYLQJV \HDU

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This sample calculation does not include a value for savings due to correct TDS control and
reduced blowdown, which will further reduce water losses and boiler chemical costs. These can
vary substantially from location to location, but should always be considered in the final analysis.
Clearly, when assessing condensate management for a specific project, such savings must be
determined and included.
TDS control and water treatment have already been discussed in Block 3.
The routines outlined in Examples 14.1.2 and 14.1.3 may be developed to form the basis of a forced
path calculation to assign a monetary value to projects intended to improve condensate recovery.
Equation 14.1.1 can be used to calculate the fuel savings per year:
;$%&'
)XHOVDYLQJV \HDU Equation 14.1.1
(
Where:
X = Expected improvement in condensate return expressed as a percentage between 1 and 100
A = Cost of fuel to provide 1 GJ of energy:
If gas on an interruptible tariff costs £0.01/kWh (1 kWh = 3.6 MJ)

&RVWRI*-RIHQHUJ\ [
0-
Similarly, if oil has a calorific value of 42 MJ / l, and costs £0.15 / l

&RVWRI*-RIHQHUJ\ [
0-
B = Energy required per kilogram of make-up water to reach condensate temperature (kJ/kg).
This is determined by Q in Equation 2.1.4 (Q = m cp DT)
C = Average evaporation rate (kg / h)
D= Operational hours per year (h / year)
E = Boiler efficiency (%)

Savings in water costs can be determined using Equation 14.1.2:
;&' 
6DYLQJVLQZDWHUFRVWV \HDU   [&RVWRIZDWHU P Equation 14.1.2
 
Savings in effluent costs can be determined using Equation 14.1.3:
;&' 
6DYLQJVLQHIIOXHQWFRVWV \HDU   [&RVWRIHIIOXHQW P Equation 14.1.3
 
Where:
X = Expected improvement in condensate return expressed as a percentage between 1 and 100
C = Average evaporation rate (kg / h)
D= Operational hours per year (h / year)
Example 14.1.2
A major condensate management project costing £70 000 expects to recover an additional 35%
of the condensate produced at a plant.
The average boiler steaming rate is 15 000 kg / h, and the plant operates for 8 000 h / year.
The fuel used is gas on a firm tariff of £0.011 / kWh, and the boiler efficiency is estimated as 80%.
Make-up water temperature is 10°C and insulated condensate return lines ensure that condensate
will arrive back at the boiler house at 95°C.
Consider the water costs to be £0.70 / m3 and the total effluent costs to be £0.45 / m3.
o Determine the payback period for the project.
Part 1 - Determine the fuel savings

Use Equation 14.1.1:
;$%&'
)XHOVDYLQJV \HDU Equation 14.1.1
(
Where:
X = Expected improvement in condensate return = 35%

$ &RVWRISURYLGLQJ*-RIHQHUJ\ [
0-
B = Energy required per kilogram of make-up water to reach condensate temperature (kJ/kg).
This is determined by Q in Equation 2.1.4 (Q = m cp DT)
Q = m x cp x DT
Q = 1 x 4.19 x (95°C - 10°C)
Q = 356.15 kJ / kg
B = Q in Equation 2.1.4 = 356.15kJ / kg
C = Average evaporation rate = 15 000 kg / h
D = Steaming hours per year = 8 000 h
E = Boiler efficiency = 80%
Substituting the values for X, A, B, C, D, and E into Equation 14.1.1
[[[ [
)XHOVDYLQJV \HDU
[
)XHOVDYLQJV \HDU

Part 2 - Determine the water and effluent savings

Use Equation 14.1.2 to calculate the savings in water costs / year:
;&' 
6DYLQJVLQZDWHUFRVWV \HDU   [&RVWRIZDWHU P Equation 14.1.2
 
Substituting values into Equation 14.1.2:

[ [ 
6DYLQJVLQZDWHUFRVWV \HDU   [ P
 
6DYLQJVLQZDWHUFRVWV \HDU
Use Equation 14.1.2 to calculate the savings in effluent costs / year:
;&' 
6DYLQJVLQHIIOXHQWFRVWV \HDU   [&RVWRIHIIOXHQW P Equation 14.1.3
 
Substituting values into Equation 14.1.3:
6DYLQJVLQHIIOXHQWFRVWV \HDU  [ [  [ P

 
 
6DYLQJVLQHIIOXHQWFRVWV \HDU
Total water and effluent savings / year = £29 400 + £18 900
Total water and effluent savings / year = £48 300
Part 3 - Determine the payback period

Total savings = Fuel savings + Water and effluent savings
Total savings = £57 122 + £ 48 300
Total savings = £105 422 / year
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Questions
1. When 10 kg of steam condenses at 0 bar g, how much condensate is produced?

a| 10 kg ¨
b| 1.5 kg ¨
c| 10% of the mass of the steam ¨
d| 10% of the volume of the steam ¨
2. 10 kg of steam condenses at 14 bar g. What proportion of the total heat in the steam is
held in the condensate?
a| 5% ¨
b| 10% ¨
c| 20% ¨
d| 30% ¨
3. A boiler produces 1 000 kg / h of steam at 7 bar g, but none of the condensate is recovered.
Approximately at what rate is energy being wasted ? (Steam tables are required).
a| 20 kW ¨
b| 40 kW ¨
c| 200 kW ¨
d| 1 000 kW ¨
4. If, in Question 3, it is proposed that 50% of the wasted condensate is to be returned

to the boiler feedtank at 90°C, and the fuel cost is £3 / GJ, the cold water make-up
temperature is 15°C, the water make-up temperature is 15°C, and the water/effluent
costs are £0.8 / m³, what are the potential total annual condensate savings if the boiler
steams at 85% efficiency for 4 000 hours per year?
a| £1 500 ¨
b| £2 218 ¨
c| £10 100 ¨
d| £500 ¨
5. If in Question 4, the cost of this project were £2 000, what would be the simple payback
term?
a| 3 weeks ¨
b| 33 weeks ¨
c| 18 months ¨
d| 47 weeks ¨
Answers
1: a, 2: d, 3: c, 4: b, 5: d

Block 14 Condensate Recovery Layout of Condensate Return Lines Module 14.2
Module 14.2
Layout of Condensate
Return Lines

Layout of Condensate Return Lines
No single set of recommendations can cover the layout of condensate pipework. Much depends
on the application pressure, the steam trap characteristics, the position of the condensate return
main relative to the plant, and the pressure in the condensate return main. For this reason it is
best to start by considering what has to be achieved, and to design a layout which will ensure
that basic good practice is met.
The prime objectives are that:
o Condensate must not be allowed to accumulate in the plant, unless the steam using apparatus
is specifically designed to operate in this way. Generally apparatus is designed to operate
non-flooded, and where this is the case, accumulated condensate will inhibit performance,
and encourage the corrosion of pipes, fittings and equipment.
o Condensate must not be allowed to accumulate in the steam main. Here it can be picked
up by high velocity steam, leading to erosion and waterhammer in the pipework.
The subject of condensate piping will divide naturally into four basic types where the
requirements and considerations of each will differ. These four basic types are defined and
illustrated in Figure 14.2.1.
Steam main
Steam flow
Drain line to trap Discharge line from trap
Common return line
Condensate flow
Type of condensate line Condensate line is sized to carry the folllowing:

Drain line to trap Condensate
Discharge line from trap Flash steam
Common return line Flash steam
Pumped return line (not shown) Condensate
Fig. 14.2.1 A steam main trap set discharging condensate into a common return line

Drain lines to steam traps

In the drain line, the condensate and any incondensable gases must flow from the drain outlet of
the plant to the steam trap.
In a properly sized drain line, the plant being drained and the body of the steam trap are virtually
at the same pressure and, because of this, condensate does not flash in this line. Gravity is the
driving force and is relied upon to induce flow along the pipe. For this reason, it makes sense for
the trap to be situated below the outlet of the plant being drained, and the trap discharge pipe to
terminate below the trap. (An exception to this is the tank heating coils discussed in Module 2.10).
The type of steam trap used (thermostatic, thermodynamic or mechanical) can affect the piping
layout.
Thermostatic steam traps
Thermostatic traps will cool condensate below saturation temperature before discharging. This
effectively waterlogs the drain line, often allowing condensate to back-up and flood the plant.
There are some applications where the sub-cooling of condensate has significant advantages
and is encouraged. Less flash steam is produced in the trap discharge line, and the introduction
of condensate into the condensate main is gentler.
Thermostatic traps discharging via open-ended pipework will waste less energy than mechanical
traps because more of the sensible heat in the waterlogged condensate imparts its heat to the
process; a typical example is that of a steam tracer line.
Thermostatic traps should not be used to drain steam mains or heat exchangers, unless proper
consideration is given to a longer and / or larger drain line to act as a reservoir and dissipate heat
to atmosphere. The extra length (or larger diameter) of drain line required to do this is usually
impractical, as shown in Example 14.2.1.
Example 14.2.1
A 30 kW air heater is to be fitted with a DN15 thermostatic steam trap, which releases condensate
at 13°C below saturation temperature. The normal working pressure is 3 bar g, the ambient
temperature is 15°C, and the heat loss from the drain line to the environment is estimated to be
20 W / m2 °C.
Determine the minimum required length of 15 mm drain line to the thermostatic trap.
From steam tables, at 3 bar g:
Saturation temperature of steam = 144°C
Trap discharge temperature = 144 - 13°C = 131°C
Enthalpy of evaporation (hfg) = 2 133.24 kJ / kg
Equation 2.8.1 can be used to calculate the steam flow from the heat load:
/RDGLQN:[
6WHDPIORZUDWHNJ K = Equation 2.8.1
KIJ DWRSHUDWLQJSUHVVXUH
+HDWORDGN:[VK

6WHDPIORZUDWHNJ K =
KIJ DWRSHUDWLQJSUHVVXUHN-NJ
[
6WHDPIORZUDWHNJ K =

Steam flowrate = 50.6 kg / h (= 0.014 1 kg / s)

As the trap discharges at 131°C, the drain line has to emit enough heat such that the condensate
at the heater outlet is at saturation temperature, and that condensate will not back-up into the
heater. The required heat loss from the drain line can be calculated from Equation 2.6.5.
FS ∆7 Equation 2.6.5
Where:
Q = Mean heat transfer rate (kW)
m = Mean secondary fluid flowrate (kg /s)
cp = Specific heat capacity of the secondary fluid (kJ / kg K) or (kJ / kg °C) = 4.19 for water
DT = Temperature rise of the secondary fluid (K or °C)
DT in Equation 2.6.5 is the required temperature drop along the drain line of 13°C.
NJ V[N- NJ &[&
N:
This heat loss will be achieved from the mean condensate temperature along the drain line.

0HDQFRQGHQVDWHWHPSHUDWXUHLQWKHGUDLQOLQH &

The surface area of the drain line to provide the required heat loss can be calculated using
Equation 2.5.3.
8$∆7 Equation 2.5.3
Where:
Q = Heat transferred per unit time (W ( J /s))
U = Overall heat transfer coefficient (W/m² K or W/m² °C)
A = Heat transfer area (m²)
DT = Temperature difference between the primary and secondary fluid (K or °C)
Note:
Q will be a mean heat transfer rate (QM) if DT is a mean temperature difference (DTLM or DTAM).
DT in Equation 2.5.3 is the difference between the mean condensate temperature and the ambient
temperature = 137.5°C - 15°C = 122.5°C
N:
8 :P &
From Equation 2.5.3:
0.768 x 103 watts = 20 watts / m2 °C x A x 122.5°C
Therefore, A = 0.313 m2
The length of pipe required to provide this surface area can be calculated using information from
Table 2.10.3.
Table 2.10.3 Nominal surface areas of steel pipes per metre length
Nominal bore mm 15 20 25 32 40 50 65 80 100
Surface area (m²/m) 0.067 0.085 0.106 0.134 0.152 0.189 0.239 0.279 0.358
The surface area of 15 mm pipe = 0.067 m2 / m

P
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P P
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This length of pipe (4.7 m) is probably impractical in the field. Two alternatives remain. One is to
increase the diameter of the drain line, which is still usually impractical; the other is much
simpler, to fit the correct trap for this type of application; a float-thermostatic trap which discharges
condensate at steam temperature and hence requires no cooling leg.
Should a thermostatic trap be considered essential, and fitted no more than 2 metres away from
the heater outlet, it would be necessary to calculate the required diameter of drain line. The heat
loss required from the pipe remains the same, along with the total surface area of the pipe, but
the surface area per metre length must increase.
P
7KHVXUIDFHDUHDUHTXLUHG PHWUHOHQJWK
P
7KHVXUIDFHDUHDUHTXLUHG PHWUHOHQJWK P P
From Table 2.10.3, it can be seen that the minimum sized pipe to give this area per metre is a
50 mm pipe, which, again, may be construed as being impractical and expensive to fabricate.
The moral of this is that it is usually easier and cheaper to select the correct trap for the job, than
have the wrong type of trap and fabricate a solution around it.
Thermodynamic steam traps
Traps that discharge intermittently, such as thermodynamic traps, will accumulate condensate
between discharges. However, they are extremely robust, will tolerate freezing ambient
temperatures and have a relatively small outer surface area, meaning that heat loss to the
environment is minimised. They are not suitable for discharging condensate into flooded return
lines, as will be explained later in this Block.
Mechanical steam traps
Mechanical steam traps with a continuous discharge characteristic, for example float-thermostatic
traps, often prove to be the best option, and have the additional advantage of being able to vent
air.
Most float traps are available in two basic flow configurations, either horizontal or vertical flow
through the trap. Some inverted bucket traps have bottom inlet and top outlet connections.
Clearly, the trap connections will affect the path of connecting pipework.
The drain line should be kept to a minimum length, ideally less than 2 metres. Long drain lines
from the plant to the steam trap can fill with steam and prevent condensate reaching the trap.
This effect is termed steam locking. To minimise this risk, drain lines should be kept short
(see Figure 14.2.2). In situations where long drain lines are unavoidable, the steam locking
problem may be overcome using float traps with steam lock release devices. The problem of
steam locking should be tackled by fitting the correct length of pipe in the first place, if possible.
✓
✗
Fig. 14.2.2 Keep drain lines short
The detailed arrangements for trapping steam-using plant and steam mains drainage are different
as is explained in the following paragraphs.

With steam-using plant, the pipe from the condensate connection should fall vertically for about
10 pipe diameters to the steam trap. Assuming a correctly sized ball float trap is installed, this will
ensure that surges of condensate do not accumulate in the bottom of the plant with its attendant
risks of corrosion and waterhammer. It will also provide a small amount of static head to help
remove condensate during start-up when the steam pressure might be very low. The pipework
should then run horizontally, with a fall in the direction of flow to ensure that condensate flows
freely (see Figure 14.2.3).
Steam main
Steam
Air heater battery

Slight fall in the
direction of flow
➤
10 D
➤
➤
➤
D Condensate
Fig. 14.2.3 Ideal arrangement when draining a steam plant
With steam mains drainage, provided drain pockets are installed as recommended in Module 10.3,
then the drain line between the pocket and the steam trap may be horizontal. If the drain pocket
is not as deep as the recommendation, then the steam trap should be fitted an equivalent distance
below it (see Figure 14.2.4).
D Steam main Steam
d
d2 Drain
pocket
Float trap Check valve
Strainer
Sight glass
Condensate
Main diameter D Pocket diameter d1 Pocket depth d2

Up to 100 mm d1 = D Minimum d2 = 100 mm
125 mm - 200 mm d1 = 100 mm Minimum d2 = 150 mm
250 mm and above d1 = D/2 Minimum d2 = D
Fig. 14.2.4 Ideal arrangement when draining a steam main

Discharge lines from traps

These pipes will carry condensate, incondensable gases, and flash steam from the trap to the
condensate return system (Figure 14.2.5). Flash steam is formed as the condensate is discharged
from the high-pressure space before the steam trap to the lower pressure space of the condensate
return system. (Flash steam is discussed briefly in Module 14.1, and in more detail in Module 2.2).
These lines should also fall in the direction of flow to maintain free flow of condensate. On
shorter lines, the fall should be discernible by sight. On longer lines, the fall should be about
1:70, that is, 100 mm every 7 metres.
Condensate
Condensate
High pressure Check Isolating Low pressure and flash
drain line Float trap valve valve discharge line steam
Fig. 14.2.5 Trap discharge lines pass condensate, flash and incondensibles
Discharging into flooded return lines

Discharging traps into flooded return lines is not recommended, especially with blast action traps
(thermodynamic or inverted bucket types), which remove condensate at saturation temperature.
Good examples of flooded condensate mains are pumped return lines and rising condensate
lines. They often follow the same route as steam lines, and it is tempting to simply connect mains
drainage steam trap discharge lines into them.
However, the high volume of flash steam released into long flooded lines will violently push the
water along the pipe, causing waterhammer, noise and, in time, mechanical failure of the pipe.
Common return lines

Where condensate from more than one trap flows to the same collecting point such as a vented
receiver, it is usual to run a common line into which individual trap discharge lines are connected.
Provided the layouts as featured in Figures 14.2.6/7/8 and 10 are observed, and the pipework is
adequately sized as indicated in Module 14.3, this is not a problem.
Blast discharge traps
If blast discharge traps (thermodynamic or inverted bucket types) are used, the reactionary forces
and velocities can be high. Swept tees will help to reduce mechanical stress and erosion at the
point where the discharge line joins the common return line (see Figure 14.2.6).
Steam Steam main
Swept tee
Common return line

Condensate
Fig. 14.2.6 A swept tee connection

Continuous discharge traps

If, for some reason, swept tees cannot be used, a float-thermostatic trap with its continuous
discharge action is a better option (Figure 14.2.7). The flooded line will absorb the dissipated
energy from the (relatively small) continuous flow from the float-thermostatic trap, more easily.
It the pressure difference between the steam and condensate mains is very high, then a diffuser
will help to cushion the discharge, reducing both erosion and noise.
Diffuser
Condensate Condensate in
flooded line
Condensate
Steam Steam main
Float-thermostatic trap
Fig. 14.2.7 Float trap with a diffuser into a flooded line
Another alternative is to use a thermostatic trap that holds back condensate until it cools below
the steam saturation temperature; this reduces the amount of flash steam formed (Figure 14.2.8).
To avoid waterlogging the steam main, the use of a generous collecting pocket on the main, plus
a cooling leg of 2 to 3 m of unlagged pipe to the trap is essential. The cooling leg stores condensate
while it is cooling to the discharge temperature.
If there is any danger of waterlogging the steam main, thermostatic traps should not be used.
Diffuser
Condensate Condensate in
flooded line
Condensate
Steam Steam main
Balanced pressure
thermostatic trap
Thermostatic trap set with cooling leg
Fig. 14.2.8 Balanced pressure thermostatic trap with cooling leg into a flooded line
Temperature controlled plant with steam traps draining into flooded lines
Processes using temperature control provide an example where the supply steam pressure is
throttled across a control valve. The effect of this is to reduce steam trap capacity to a point
where the condensate flow can stop completely, and the system is said to have stalled. The
subject of stall is discussed in greater depth in Block 13.
Stall occurs as a result of insufficient steam pressure to purge the steam plant of condensate, and
is more likely when the plant has a high turndown from full-load to part load.

Not all temperature controlled systems will stall, but the backpressure caused by the condensate
system could have an adverse effect on the performance of the trap. This in turn, might impair
the heat transfer capability of the process (Figure 14.2.9).
Condensate drain lines should, therefore, be configured so that condensate cannot flood the
main into which they are draining as depicted in Figure 14.2.10.
Lifting common line
causing backpressure
and flooding
Steam
Temperature control may

cause low condensate
Heat exchanger
✗
Condensate from others
pressure in the drain line
Steam trap
Flooded common line
Fig. 14.2.9 Discharge from steam traps on temperature controlled equipment into flooded lines
should be avoided if possible
✓
Vacuum breaker
Steam
Heat exchanger
Temperature control may Condensate from others

cause low condensate Slope 1:70
pressure in the drain line
➤
➤
Steam trap Falling common line

Non-flooded common line
allowing condensate
Condensate draining down to a vented receiver to drain freely.
Fig. 14.2.10 Condensate discharging freely via a falling common line
Discharge lines at different pressures

Condensate from more than one temperature controlled process may join a common line, as
long as this line is:
o Designed to slope in the direction of flow to a collection point.
o Sized to cater for the cumulative effects of any flash steam from each of the branch lines at full-load.
The concept of connecting the discharges from traps at different pressures is sometimes
misunderstood.
If the branch lines and the common line are correctly sized, the pressures downstream of each
trap will be virtually the same. However, if these lines are undersized, the flow of condensate
and flash steam will be restricted, due to a build up of backpressure caused by an increased
resistance to flow within the pipe. Condensate flowing from traps draining the lower pressure
systems will tend to be the more restricted.
Each part of the discharge piping system should be sized to carry any flash steam present at
acceptable steam velocities. The discharge from a high-pressure trap will not interfere with that
from a low-pressure trap if the discharge lines and common line are properly sized and sloped in
the direction of flow. Module 14.3, Sizing of condensate return lines gives further details.

Pumped return lines

Flash steam may, at some point, be separated from the condensate and used in a recovery
system, or simply vented to atmosphere from a suitable receiver (Figure 14.2.11). The residual
hot condensate from the latter can be pumped on to a suitable collecting tank such as a boiler
feedtank. When the pump is served from a vented receiver, the pumped return line will be fully
flooded with condensate at temperatures below 100°C, which means flash steam is less likely to
occur in the line.
Vent
Condensate
pumped
to boiler
feedtank High level
condensate
Steam Steam Steam Condensate main
receiver
MFP
Pump
Fig. 14.2.11 Condensate recovery from a vented receiver
Flow in a pumped return line is intermittent, as the pump starts and stops according to its needs.
The pump discharge rate will be higher than the rate at which condensate enters the pump. It is,
therefore, the pump discharge rate which determines the size of the pump discharge line, and
not the rate at which condensate enters the pump.
The pumping of condensate is discussed in further detail in Module 14.4, Pumping condensate
from vented receivers.

Questions
1. How many different basic types of condensate lines are there?

a| One ¨
b| Two ¨
c| Three ¨
d| Four ¨
2. Why are thermostatic traps not recommended for draining steam mains?
a| They tend to waterlog the drain line ¨
b| They tend to waterlog the process ¨
c| Long drain lines are necessary to cool the condensate ¨
d| All of the above ¨
3. When might a thermostatic trap be used to drain a steam main?

a| When it is fitted to a correctly sized drain pocket ¨
b| When the difference in pressure between the steam and condensate is high ¨
c| When it is fitted with a cooling leg and draining into a flooded main ¨
d| Never ¨
4. When are thermodynamic traps not recommended for draining steam mains?
a| They are not intended to drain steam mains ¨
b| When draining into flooded condensate lines ¨
c| When fitted outside and there is a danger of freezing ¨
d| When fitted to large drain pockets ¨
5. What will a trap discharge line normally carry that a drain line does not?
a| The weight of the trap ¨
b| Live steam ¨
c| A mixture of live steam and condensate ¨
d| A mixture of flash steam and condensate ¨
6. Upon which criterion is a pump discharge line sized?

a| The condensate discharge rate from the pump ¨
b| The pump filling rate ¨
c| The size of the pump outlet ¨
d| The height of the process above the top of the pump ¨
Answers
1: d, 2: d, 3: c, 4: b, 5: d, 6: a


Block 14 Condensate Recovery Sizing Condensate Return Lines Module 14.3
Module 14.3
Sizing Condensate
Return Lines

Sizing Condensate Lines

The four main types of condensate line, as mentioned in Module 14.2, are shown in Table 14.3.1:
Table 14.3.1 The four basic types of condensate line
Type of condensate line Condensate line is sized to carry the following
Drain lines to trap Condensate
Discharge lines from traps Flash steam
Common return lines Flash steam
Pumped return lines Condensate
Sizing of all condensate lines is a function of:

o Pressure - The difference in pressure between one end of the pipe and the other. This pressure
difference may either promote flow, or cause some of the condensate to flash to steam.
o Quantity - The amount of condensate to be handled.
o Condition - Is the condensate predominately liquid or flash steam?
With the exception of pumped return lines which will be discussed in Module 14.4, the other
three main types of condensate line and their sizing, will be covered in this Module.
Sizing drain lines to traps

It should not be assumed that the drain line (and trap) should be the same size as the plant outlet
connection. The plant may operate at a number of different operating pressures and flowrates,
especially when it is temperature controlled. However, once the trap has been correctly sized,
it is usually the case that the drain line will be the same size as the trap inlet connection,
(see Figure 14.3.1).
Plant DN20 outlet

✗
20 mm pipe
Plant DN20 outlet
25 mm pipe
✓ DN25
trap
Fig. 14.3.1 The drain line should not be sized on the plant connection
Regarding the conditions inside the drain line, as there is no significant pressure drop between the
plant and the trap, no flash steam is present in the pipe, and it can be sized to carry condensate only.
When sizing the drain line, the following will need consideration:
o The condensing rate of the equipment being drained during full-load.
o The condensing rate of the equipment at start-up.
At plant start-up, the condensing rate can be up to three times the running load this is where
the temperature difference between the steam and colder product is at its maximum.
The drain line, trap, and discharge line also have to carry the air that is displaced by the
incoming steam during this time.
The sizing routine for the steam trap will have to consider both of these variables, however, in
general:
o For steam mains drainage, the condensate load for each drain trap is typically 1% of the steam
capacity of the main based on drain points at 50 m intervals, and with good insulation.
For most drain points, sizing the trap to pass twice the running load at the working pressure
(minus any backpressure) will allow it to cope with the start-up load.

o On constant steam pressure processes such as presses, ironers, unit heaters, radiant panels
and boiling pans, sizing the traps on approximately twice the running load at the working
pressure (less any backpressure) will provide sufficient capacity to cope with the start-up load.
o On temperature controlled applications, the steam pressure, the plant turndown, the set
temperature and steam trap location need to be considered in detail, and the trap needs to be
sized to cater for both the full and minimum load conditions. If these conditions are not known
it is recommended that the steam trap be sized on 3 x the running load at the running differential
pressure. This should satisfy the start-up condition and provide proper drainage at minimum
loads.
When the trap is sized in this way, it will also cater for the start-up load. Consequently, if the
drain line to the trap is sized on the trap size, it will never be undersized.
For practical purposes, where the drain line is less than 10 m, it can be the same pipe size as the
steam trap selected for the application. Drain lines less than 10 m long can also be checked
against Appendix 14.3.1 and a pipe size should be selected which results in a pressure loss at
maximum flowrate of not more than 200 Pa per metre length, and a velocity not greater than
1.5 m / s. Table 14.3.2 is an extract from Appendix 14.3.1.
On longer drain lines (over 10 m), the pressure loss at maximum flowrate should not be more
than 100 Pa /m, and a velocity not greater than 1 m / s.
Table 14.3.2 Flow of water in heavy steel pipes
Flowrate Capacity kg / h
Pipe size Ø 15 mm 20 mm 25 mm 32 mm 40 mm 50 mm 65 mm 80 mm 100 mm
Pa / m mbar / m <0.15 m / s 0.15 m / s 0.3 m / s
90.0 0.900 173 403 745 1 627 2 488 4 716 9 612 14 940 30 240
92.5 0.925 176 407 756 1 652 2 524 4 788 9 756 15 156 30 672
95.0 0.950 176 414 767 1 678 2 560 4 860 9 900 15 372 31 104
97.5 0.975 180 421 778 1 699 2 596 4 932 10 044 15 552 31 500
1.0 m / s
100.0 1.000 184 425 788 1 724 2 632 5 004 10 152 15 768 31 932
120.0 1.200 202 472 871 1 897 2 898 5 508 11 196 17 352 35 100
140.0 1.400 220 511 943 2 059 3 143 5 976 12 132 18 792 38 160
160.0 1.600 234 547 1 015 2 210 3 373 6 408 12 996 20 160 40 680
180.0 1.800 252 583 1 080 2 354 3 589 6 804 13 824 21 420 43 200
200.0 2.000 266 619 1 141 2 488 3 780 7 200 14 580 22 644 45 720
220.0 2.200 281 652 1 202 2 617 3 996 7 560 15 336 23 760 47 880
240.0 2.400 288 680 1 256 2 740 4 176 7 920 16 056 24 876 50 400 1.5 m / s
260.0 2.600 306 713 1 310 2 855 4 356 8 244 16 740 25 920 52 200
280.0 2.800 317 742 1 364 2 970 4 536 8 568 17 388 26 928 54 360
300.0 3.000 331 767 1 415 3 078 4 680 8 892 18 000 27 900 56 160
Example 14.3.1
An item of plant, using steam at constant pressure, condenses 470 kg of steam an hour at full-
load. The pipework between the plant item and the steam trap has an equivalent length of 2 m.
Determine the size of pipe to be used.
Revised load allowing for start-up = 470 kg / h x 2 = 940 kg / h.
As the pipe length is less than 10 metres, the maximum allowable pressure drop is 200 Pa /m.
Using Table 14.3.1, by looking across from 200 Pa /m it can be seen that a 25 mm pipe has a
capacity of 1 141 kg / h, and would therefore be suitable for the expected starting load of 940 kg /h.
Checking further up the 25 mm column, it can be seen that a flowrate of 940 kg / h will incur an
actual pressure drop of just less than 140 Pa /m flowing through a 25 mm pipe.

Sizing discharge lines from traps

The section of pipeline downstream of the trap will carry both condensate and flash steam at the
same pressure and temperature. This is referred to as two-phase flow, and the mixture of liquid
and vapour will have the characteristics of both steam and water in proportion to how much of
each is present. Consider the following example.
Example 14.3.2
An item of plant uses steam at a constant 4 bar g pressure. A mechanical steam trap is fitted, and
condensate at saturation temperature is discharged into a condensate main working at 0.5 bar g.
Determine the proportions by mass, and by volume, of water and steam in the condensate main.
Part 1 - Determine the proportions by mass
From steam tables:
At 4.0 bar g hf = 640.7 kJ / kg
At 0.5 bar g hf = 464.1 kJ / kg hfg = 2 225.6 kJ / kg
Equation 2.2.5 is used to determine the proportion of flash steam:
KI DW3 KI DW3

3URSRUWLRQRIIODVKVWHDP = Equation 2.2.5
KIJ DW3
Where:
P1 = Initial pressure
P2 = Final pressure
hf = Specific liquid enthalpy (kJ /kg)
hfg = Specific enthalpy of evaporation (kJ /kg)

3URSRUWLRQRIIODVKVWHDP = [

Clearly, if 7.9% is flashing to steam, the remaining 100 7.9 = 92.1% of the initial mass flow will
remain as water.
Part 2 - Determine the proportions by volume
Based on an initial mass of 1 kg of condensate discharged at 4 bar g saturation temperature, the
mass of flash steam is 0.079 kg and the mass of condensate is 0.921 kg (established from Part 1).
Water:
The density of saturated water at 0.5 bar g is 950 kg / m3,

DQGWKHYROXPHRFFXSLHGE\NJ P

Steam:
From steam tables, specific volume (vg) of steam at 0.5 bar g = 1.15 m3 / kg
The volume occupied by the steam is 0.079 kg x 1.15 m3 / kg = 0.091 m3
The total volume occupied by the steam and condensate mixture is:
0.001 m3 (water) + 0.091 m3 (steam) = 0.092 m3
By proportion (%):

7KHZDWHURFFXSLHV [ VSDFH

7KHVWHDPRFFXSLHV [ VSDFH

From this, it follows that the two-phase fluid in the trap discharge line will have much more in
common with steam than water, and it is sensible to size on reasonable steam velocities rather
than use the relatively small volume of condensate as the basis for calculation. If lines are
undersized, the flash steam velocity and backpressure will increase, which can cause waterhammer,
reduce the trap capacity, and flood the process.

Steam lines are sized with attention to maximum velocities. Dry saturated steam should travel no
faster than 40 m /s. Wet steam should travel somewhat slower (15 to 20 m /s) as it carries moisture
which can otherwise have an erosive and damaging effect on fittings and valves.
Trap discharge lines can be regarded as steam lines carrying very wet steam, and should be sized
on similarly low velocities.
Condensate discharge lines from traps are notoriously more difficult to size than steam lines due
to the two-phase flow characteristic. In practice, it is impossible (and often unnecessary) to
determine the exact condition of the fluid inside the pipe.
Although the amount of flash steam produced (see Figure 14.3.2) is related to the pressure difference
across the trap, other factors will also have an effect.

15
14
ar g
ar g
ar g
ar g
ar g
rg
13
0 ba
2.0 b
2 .5 b
0.5 b
1.0 b
1.5 b
12
11
10
9
Pressure on traps bar
4
Atmospheric pressure
3
0
0 0.02 0.06 0.10 0.14 0.18 0.22
10%
kg Flash steam / kg condensate
Fig. 14.3.2 Quantity of flash steam graph
Factors having a bearing on two-phase flow inside a pipe, include:

o If the condensate on the upstream side of the trap is cooler than the saturation temperature
(for example: a thermostatic steam trap is used), the amount of flash steam after the trap is
reduced. This can reduce the size of the line required.
o If the line slopes down from the trap to its termination, the slope will have an effect on the
flow of condensate, but to what magnitude, and how can this be quantified?

o On longer lines, radiation losses from the line may condense some of the flash steam, reducing
its volume and velocity, and there may be a case for reducing the line size. But at what point
should it be reduced and by how much?
o If the discharge line lifts up to an overhead return line, there will be times when the lifting line
will be full of cool condensate, and times when flash steam from the trap may evaporate some
or all of this condensate. Should the rising discharge line be sized on flash steam velocity or
the quantity of condensate?
o Most processes operate some way below their full-load condition for most of their running
cycle, which reduces flash steam for most of the time. The question therefore arises: is there a
need for the system to be sized on the full-load condition, if the equipment permanently
runs at a lower running load?
o On temperature controlled plant, the pressure differential across the trap will itself change
depending on the heat load. This will affect the amount of flash steam produced in the line.
Recommendations on trap discharge lines

Because of the number of variables, an exact calculation of line size would be complex and
probably inaccurate. Experience has shown that if trap discharge lines are sized on flash steam
velocities of 15 to 20 m / s, and certain recommendations are adhered to, few problems will arise.
Recommendations:
1. Correctly sized trap discharge lines which slope in the direction of flow and are open-ended
or vented at a receiver, will be non-flooded and allow flash steam to pass unhindered above the
condensate (Figure 14.3.3). A minimum slope of 1 in 70 (150 mm drop every 10 m) is
recommended. A simple visual check will usually confirm if the line is sloping - if no slope is
apparent it is not sloping enough!
Vent
Easy passage for flash steam

Process
Steam
Pumped
Easy passage for condensate
condensate
Vented
receiver
1:70 slope = 150 mm per 10 m run
Pump
Fig. 14.3.3 Discharge line sloping 1:70 in the direction of flow

2. If it is unavoidable, non-pumped rising lines (Figure 14.3.4) should be kept as short as possible and
fitted with a non-return valve to stop condensate falling back down to the trap. Risers should
discharge into the top of overhead return lines. This stops condensate draining back into the
riser from the return main after the trap has discharged, to assist the easy passage of flash steam
up the riser.

Vent
Condensate from others

1:70 slope =
150 mm per 10 m run
Common
return line Pumped
condensate
Non pumped
rising line
Flash steam has to Vented

Process pass through the receiver
condensate
Steam
Pump
Fig. 14.3.4 Keep rising lines short and connect to the top of return lines
It is sensible to consider using a slightly larger riser, which will produce a lower flash steam velocity.
This will reduce the risk of waterhammer and noise caused by steam trying to force a path
through the liquid condensate in the riser.
Important: A rising line should only be used where the process steam pressure is guaranteed
to be higher than the condensate backpressure at the trap outlet. If not, the process will
waterlog unless a pumping trap or pump-trap combination is used to provide proper drainage
against the backpressure.
3. Common return lines should also slope down and be non-flooded (Figure 14.3.4). To avoid
flash steam occurring in long return lines, hot condensate from trap discharge lines should
drain into vented receivers (or flash vessels where appropriate), from where it can be pumped
on to its final destination, via a flooded line at a lower temperature.
Condensate pumping is dealt with in more detail in Module 14.4.
The condensate pipe sizing chart

The condensate pipe sizing chart (Figure 14.3.5) can be used to size any type of condensate line,
including:
o Drain lines containing no flash steam.
o Lines consisting of two-phase flow, such as trap discharge lines, which are selected according
to the pressures either side of the trap.
The chart (Figure 14.3.5):
o Works around acceptable flash steam velocities of 15 - 20 m/ s, according to the pipe size and
the proportion of flash steam formed.
o Can be used with condensate temperatures lower than the steam saturation temperature,
as will be the case when using thermostatic steam traps.
o Is used to size trap discharge lines on full-load conditions. It is not necessary to consider
any oversizing factors for start-up load or the removal of non-condensable gases.
o May also be used to estimate sizes for pumped lines containing condensate below 100°C. This
will be discussed in Module 14.4.

Condensate pipe size mm

500 400 350 300 250 200
100000
150
50000 100
80
20000
65
10000 50
5000 40

Codensate flowrate kg/h
32
2000 25
5
1000
20
500 15
10
200
100 6
50
20
10
1
3 4 2
250 50
40
Condensate system pressure bar g
Steam system pressure bar g
20 30
Steam temperature °C
200 2
20
10
180 10
5 1
160 5
4
140
2 3 2
120 1 1
0.5 0.5
100 0 0
Fig. 14.3.5 Condensate pipe sizing chart
Using the condensate pipe sizing chart (Also available in Appendix 14.3.2)
Establish the point where the steam and condensate pressures meet (lower part of the chart,
Figure 14.3.5). From this point, move vertically up to the upper chart to meet the required
condensate rate. If the discharge line is falling (non-flooded) and the selection is on or between
lines, choose the lower line size. If the discharge line is rising, and therefore likely to be flooded,
choose the upper line size.
Note: The reasoning employed for the sizing of a steam trap is different to that used for a discharge
line, and it is perfectly normal for a trap discharge line to be sized different to the trap it is serving.
However, when the trap is correctly sized, the usual ancillary equipment associated with a steam
trap station, such as isolation valves, strainer, trap testing chamber, and check valve, can be the
same size as the trapping device selected, whatever the discharge line size.

Example 14.3.3 1 on the chart (Figure 14.3.6)

A steam trap passing a full-load of 1 000 kg / h at 6 bar g saturated steam pressure through a falling
discharge line down to a flash vessel at 1.7 bar g.
As the discharge line is non-flooded, the lower figure of 25 mm is selected from the chart
(Figure 14.3.4).
6 bar g
High pressure steam

Shell and tube
heat exchanger
Low pressure steam

Float trap set
1.7 bar g
Discharge line being sized

Pipeline size selected by use Flash vessel
of the chart, Figure 14.3.5, is
Ø25 mm
Condensate
Fig. 14.3.6 A non-flooded pressurised trap discharge line (refer to Example 14.3.3)

A steam trap passing a full-load of 1 000 kg / h at 18 bar g saturated steam pressure through a
discharge line rising 5 m up to a pressurised condensate return line at 3.5 bar g.
Add the 0.5 bar static pressure (5 m head) to the 3.5 bar condensate pressure to give 4 bar g
backpressure.
As the discharge line is rising and thus flooded, the upper figure of 32 mm is selected from the
chart, (Figure 14.3.4).
18 bar g
High pressure steam 3.5 bar g
Air vent
5 m (0.5 bar g static pressure)
Float trap
Pipeline size selected by use of the
SA control valve acting as an air vent chart, Figure 14.3.5, is Ø32 mm
and condensate drain on start-up
Fig. 14.3.7 A flooded trap discharge line (refer to Example 14.3.4)


A steam trap passing a full-load of 200 kg / h at 2 bar g saturated steam pressure through a sloping
discharge line falling down to a vented condensate receiver at atmospheric pressure (0 bar g).
As the line is non-flooded, the lower figure of 20 mm is selected from the chart, (Figure 14.3.4).
2 bar g
High pressure steam
Plate heat exchanger

Pipeline size selected by use of
the chart, Figure 14.3.5, is
Ø20 mm
Vent To high level
condensate return line
Fig. 14.3.8 A non-flooded vented trap discharge line (refer to Example 14.3.5)

A pump-trap passing a full-load of 200 kg / h at 4 bar g saturated steam space pressure through a
discharge line rising 5 m up to a non-flooded condensate return line at atmospheric pressure.
The 5 m static pressure contributes the total backpressure of 0.5 bar g.
As the trap discharge line is rising, the upper figure of 25 mm is selected from the chart,
(Figure 14.3.4).

Pipeline size selected by use of
the chart, Figure 14.3.5, is
Ø25 mm
4 bar g
High pressure steam
5 m (0.5 bar g at static pressure)
Air flow
Fig. 14.3.9 A flooded trap discharge line (refer to Example 14.3.6)


Consider a condensate load of 200 kg / h to a receiver and pump. The pump discharge rate for
this mechanical type pump is taken as six times the filling rate, hence, the condensate rate taken for
this example is 6 x 200 = 1 200 kg/ h.
Because the condensate will have lost its flash steam content to atmosphere via the receiver vent,
the pump will only be pumping liquid condensate. In this instance, it is only necessary to use the
top part of the chart in Figure 14.3.5. As the line from the pump is rising, the upper figure of 25
mm is chosen.
Note: If the pumped line were longer than 100 m, the next larger size must be taken, which for
this example would be 32 mm. A useful tip for lines of 100 m or less is to choose a discharge pipe
which is the same size as the pump. For further details refer to Module 14.1 Pumping condensate
from vented receivers.
Vent
Sloping non-flooded return line

Condensate in pipeline size selected by use of
(200 kg / h) the chart, Figure 14.3.5,
is Ø25 mm
Pumped
condensate out
(1 200 kg / h)
Fig. 14.3.10 A discharge line from the condensate pump (refer to Example 14.3.7)

Common return lines - falling lines

It is sometimes necessary to connect several trap discharge lines from separate processes into a
common return line. Problems will not occur if the following considerations are met:
o The common line is not flooded and slopes in the direction of flow to an open end or a vented
receiver, or a flash vessel if the conditions allow.
o The common line is sized on the cumulative sizes of the branch lines, and the branch lines are
sized from Figure 14.3.5.
Example 14.3.8
Figure 14.3.11 shows three heat exchangers, each separately controlled and operating at the
same time. The condensate loads shown are full loads and occur with 3 bar g in the steam space.
The common line slopes down to the flash vessel at 1.5 bar g, situated in the same plant room.
Condensate in the flash vessel falls via a float trap down to a vented receiver, from where it is
pumped directly to the boiler house.
The trap discharge lines are sized on full-load with steam pressure at 3 bar g and condensate
pressure of 1.5 bar g, and as each is not flooded, the lower line sizes are picked from the graph.
Determine the condensate line sizes for the falling discharge lines and common lines.
HE1 HE2 HE3
3 bar g 3 bar g 3 bar g

Flash
Full-load Full-load Full-load steam
750 kg / h 750 kg / h 375 kg / h
1 2 3
Ø15 1.5 bar g
1 FT14HC Ø20 mm 1 FT14HC Ø20 mm 1 FT14
mm
Ø20 mm Ø28 mm Ø32 mm
To receiver
Fig. 14.3.11 Refer to Example 14.3.8
Using Appendix 14.3.2, Condensate pipe sizing chart:

Line 1 picked as 20 mm, 2 picked as 20 mm, 3 picked as 15 mm
The bore of the common line connecting two discharge lines can be found by calculating the
square root of the sum of the squares of the bores of the two discharge lines, as shown below:
Common line for 1 + 2 , = Ö 20² + 20² = 28 mm : Pick a DN25 pipe (see note below)
Common line for ( 1 + 2 )+ 3 = Ö 28² + 15² = 32 mm : Pick a DN32 pipe
Note: The theoretical dimension of 28 mm for the common line 1 + 2 does not exist as a
nominal bore in commercial pipe sizes. The internal diameters of pipes can be larger or smaller
than the nominal bore depending on the pipe schedule. For example, for a DIN 2448 steel
pipe, the internal diameter for a 25 mm pipe is about 28.5 mm, while that for a 25 mm
Schedule 40 pipe is about 26.6 mm.
Where the calculated bore is not much greater than the nominal bore, it is practical to choose the
next lower size pipe. In this instance, a nominal bore 25 mm pipe may be selected. If, however,
the calculated bore is not near the nominal bore, then the next larger nominal bore pipe should
be selected. Common sense should be applied.

Common return lines - rising lines

It is sometimes unavoidable for condensate discharge and common lines to rise at some point
between the trap and the point of final termination. When this is the case, each discharge line is
sized by moving up to the next size on the chart, as previously discussed in this Module.
Example 14.3.9
Figure 14.3.12 shows the same three heat exchangers as in Example 14.3.8.
However, in this instance, the common line rises 15 m and terminates in an overhead non-
flooded condensate return main, giving the same backpressure of 1.5 bar as in Example 14.3.8.
Each of the discharge lines is sized as a rising line.
Determine the condensate line sizes for the discharge lines and common lines.
1.5 bar g
HE1 HE2 HE3
3 bar g 3 bar g 3 bar g 15 m
Full-load Full-load Full-load

750 kg / h 750 kg / h 375 kg / h
1 2 3
1 FT14HC Ø25 mm 1 FT14HC Ø25 mm Ø20
1 FT14
mm
Ø25 mm Ø40 mm Ø50 mm
Fig. 14.3.12 Refer to Example 14.3.9
Using Appendix 14.3.2, Condensate pipe sizing chart:
Line 1 picked as 25 mm, 2 picked as 25 mm, 3 picked as 20 mm
Because the common line is rising, it can be seen that each of the discharge lines is a size larger
than in Example 14.3.8 even though the backpressure is the same at 1.5 bar g.
The bore of the common line connecting two discharge lines can be found by calculating the
square root of the sum of the squares of the bores of the two discharge lines, as shown below:
Common line for 1 + 2 , = Ö 25² + 25² = 36 mm : Pick a DN40 pipe
Common line for ( 1 + 2 )+ 3 = Ö 36² + 20² = 42 mm : Pick a DN50 pipe
Note: For rising lines, the chosen nominal bore pipe should always be larger than the calculated
bore.

Example 14.3.10 - Falling common line

Calculating the common line sizes for the application shown in Fig. 14.3.12 which falls to a final
termination point:
Ø15 mm Ø40 mm Ø25 mm Ø20 mm Ø25 mm Ø32 mm
A B D F H K
C E G J L
? ? ? ? ?
Falling line to
termination
Line Pipeline diameter (mm) Commercial pipe size selected (DN)

A 15
B 40
C Ö 40²+15² = 43* 40*
D 25
E Ö 25²+43² = 50 50
F 20
G Ö 20²+50² = 54 65
H 25
J Ö 25²+54² = 60 65
K 32
L Ö 32²+60² = 68* 65*
Fig. 14.3.13 *Close to nominal bore size

Example 14.3.11 - Rising common line

Calculating the common line sizes for the application shown in Fig. 14.3.14 which rises to a final
termination point:
Note that the steam loads are the same as Example 14.3.10, but the discharge lines are one size
larger due to the rising common line.
Rising line to
Ø20 mm Ø50 mm Ø32 mm Ø25 mm Ø32 mm Ø40 mm termination
A B D F H K
C E G J L
? ? ? ? ?
Line Pipeline diameter (mm) Commercial pipe size selected (DN)

A 20
B 50
C Ö 50²+20² = 54* 50*
D 32
E Ö 32²+54² = 63 65
F 25
G Ö 25²+63² = 68* 65*
H 32
J Ö 32²+68² = 75 80
K 40
L Ö 40²+75² = 85* 80*
Fig. 14.3.14 *Close to nominal bore size
The procedure shown in Examples 14.3.10 and 14.3.11 can be simplified by using Appendix 14.3.3.
For example, where pipes A and B (20 mm and 50 mm) join, the minimum required pipe diameter
is shown as 54 mm. Clearly, the user would fit the next largest size of commercial pipe available,
unless the calculated bore is close to a nominal bore size pipe.

Appendix 14.3.1 Flow of water in heavy steel pipes

Flowrate kg / h
Pa / m mbar / m <0.15 m / s 0.15 m / s 0.3 m / s
10.0 0.100 50 119 223 490 756 1 447 2 966 4 644 9 432
12.5 0.125 58 133 252 554 853 1 634 3 348 5 220 10 656
15.0 0.150 65 151 277 616 943 1 807 3 708 5 760 11 736
17.5 0.175 68 162 302 670 1 026 1 966 4 032 6 264 12 744
20.0 0.200 76 176 328 720 1 105 2 113 4 320 6 732 13 680
22.5 0.225 79 187 349 770 1 177 2 254 4 608 7 164 14 580 0.5
25.0 0.250 83 198 371 814 1 249 2 387 4 860 7 596 15 408 m/s
27.5 0.275 90 209 389 857 1 314 2 513 5 112 7 992 16 200
30.0 0.300 94 220 410 900 1 379 2 632 5 364 8 352 16 956
32.5 0.325 97 230 428 940 1 440 2 747 5 616 8 712 17 712
35.0 0.350 101 241 446 979 1 498 2 858 5 832 9 072 18 432
37.5 0.375 104 248 464 1 015 1 555 2 966 6 048 9 396 19 116
40.0 0.400 112 259 479 1 051 1 609 3 071 6 264 9 720 19 764
42.5 0.425 115 266 497 1 087 1 663 3 175 6 480 10 044 20 412
45.0 0.450 119 277 511 1 123 1 717 3 272 6 660 10 368 21 024
47.5 0.475 122 284 526 1 156 1 768 3 370 6 876 10 656 21 636
50.0 0.500 126 292 540 1 188 1 814 3 463 7 056 10 944 22 212
52.5 0.525 130 299 558 1 220 1 865 3 553 7 236 11 232 22 788
55.0 0.550 130 306 572 1 249 1 912 3 636 7 416 11 520 23 364
57.5 0.575 133 317 583 1 282 1 958 3 744 7 596 11 808 23 904
60.0 0.600 137 324 598 1 310 2 002 3 816 7 776 12 060 24 444
62.5 0.625 140 331 612 1 339 2 048 3 888 7 920 12 312 24 984
65.0 0.650 144 338 626 1 368 2 092 3 996 8 100 12 600 25 488
67.5 0.675 148 346 637 1 397 2 131 4 068 8 280 12 852 25 992
70.0 0.700 151 353 652 1 422 2 174 4 140 8 424 13 068 26 496
72.5 0.725 151 356 662 1 451 2 218 4 212 8 568 13 320 27 000
75.0 0.750 155 364 677 1 476 2 257 4 284 8 748 13 572 27 468
77.5 0.775 158 371 688 1 505 2 297 4 356 8 892 13 788 27 972
80.0 0.800 162 378 698 1 530 2 336 4 464 9 036 14 040 28 440 1
82.5 0.825 166 385 709 1 555 2 372 4 536 9 180 14 256 28 872 m/s
85.0 0.850 166 389 724 1 580 2 412 4 608 9 324 14 472 29 340
87.5 0.875 169 396 734 1 606 2 448 4 680 9 468 14 724 29 772
90.0 0.900 173 403 745 1 627 2 488 4 716 9 612 14 940 30 240
92.5 0.925 176 407 756 1 652 2 524 4 788 9 756 15 156 30 672
95.0 0.950 176 414 767 1 678 2 560 4 860 9 900 15 372 31 104
97.5 0.975 180 421 778 1 699 2 596 4 932 10 044 15 552 31 500
100.0 1.000 184 425 788 1 724 2 632 5 004 10 152 15 768 31 932
120.0 1.200 202 472 871 1 897 2 898 5 508 11 196 17 352 35 100
140.0 1.400 220 511 943 2 059 3 143 5 976 12 132 18 792 38 160
160.0 1.600 234 547 1 015 2 210 3 373 6 408 12 996 20 160 40 680
180.0 1.800 252 583 1 080 2 354 3 589 6 804 13 824 21 420 43 200 1.5
200.0 2.000 266 619 1 141 2 488 3 780 7 200 14 580 22 644 45 720 m/s
220.0 2.200 281 652 1 202 2 617 3 996 7 560 15 336 23 760 47 880
240.0 2.400 288 680 1 256 2 740 4 176 7 920 16 056 24 876 50 400
260.0 2.600 306 713 1 310 2 855 4 356 8 244 16 740 25 920 52 200
280.0 2.800 317 742 1 364 2 970 4 536 8 568 17 388 26 928 54 360
300.0 3.000 331 767 1 415 3 078 4 680 8 892 18 000 27 900 56 160

Appendix 14.3.2 Condensate pipe sizing chart

500 400 350 300 250 200
100000
150
50000 100
80
20000
65
10000 50
5000 40

Codensate flowrate kg/h
32
2000 25
1000
20
500 15
10
200
100 6
50
20
10
250 50
40 Condensate system pressure bar g
Steam system pressure bar g
20 30
Steam temperature °C
200 20
10
180 10
160 5 5
140 2 2
120 1 1
0.5 0.5
100 0 0

Appendix 14.3.3 Common pipe sizing table

D1 = Connecting branch size (N.B.)
D2 = Common pipe size
D1 - Connecting branch size (NB) D1 - Connecting branch size (NB)
D2 D2
15 20 25 32 40 50 65 80 100 15 20 25 32 40 50 65 80 100
15 21 25 29 35 43 52 67 81 101 58 60 61 63 66 70 77 87 99 116
16 22 26 30 36 43 52 67 82 101 59 61 62 64 67 71 77 88 99 116
17 23 26 30 36 43 53 67 82 101 60 62 63 65 68 72 78 88 100 117
18 23 27 31 37 44 53 67 82 102 61 63 64 66 69 73 79 89 101 117
19 24 28 31 37 44 53 68 82 102 62 64 65 67 70 74 80 90 101 118
20 25 28 32 38 45 54 68 82 102 63 65 66 68 71 75 80 91 102 118
21 26 29 33 38 45 54 68 83 102 64 66 67 69 72 75 81 91 102 119
22 27 30 33 39 46 55 69 83 102 65 67 68 70 72 76 82 92 103 119
23 27 30 34 39 46 55 69 83 103 66 68 69 71 73 77 83 93 104 120
24 28 31 35 40 47 55 69 84 103 67 69 70 72 74 78 84 93 104 120
25 29 32 35 41 47 56 70 84 103 68 70 71 72 75 79 84 94 105 121
26 30 33 36 41 48 56 70 84 103 69 71 72 73 76 80 85 95 106 121
27 31 34 37 42 48 57 70 84 104 70 72 73 74 77 81 86 96 106 122
28 32 34 38 43 49 57 71 85 104 71 73 74 75 78 81 87 96 107 123
29 33 35 38 43 49 58 71 85 104 72 74 75 76 79 82 88 97 108 123
30 34 36 39 44 50 58 72 85 104 73 75 76 77 80 83 88 98 108 124
31 34 37 40 45 51 59 72 86 105 74 76 77 78 81 84 89 98 109 124
32 35 38 41 45 51 59 72 86 105 75 76 78 79 82 85 90 99 110 125
33 36 39 41 46 52 60 73 87 105 76 77 79 80 82 86 91 100 110 126
34 37 39 42 47 52 60 73 87 106 77 78 80 81 83 87 92 101 111 126
35 38 40 43 47 53 61 74 87 106 78 79 81 82 84 88 93 102 112 127
36 39 41 44 48 54 62 74 88 106 79 80 81 83 85 89 93 102 112 127
37 40 42 45 49 54 62 75 88 107 80 81 82 84 86 89 94 103 113 128
38 41 43 45 50 55 63 75 89 107 81 82 83 85 87 90 95 104 114 129
39 42 44 46 50 56 63 76 89 107 82 83 84 86 88 91 96 105 115 129
40 43 45 47 51 57 64 76 89 108 83 84 85 87 89 92 97 105 115 130
41 44 46 48 52 57 65 77 90 108 84 85 86 88 90 93 98 106 116 131
42 45 47 49 53 58 65 77 90 108 85 86 87 89 91 94 99 107 117 131
43 46 47 50 54 59 66 78 91 109 86 87 88 90 92 95 99 108 117 132
44 46 48 51 54 59 67 78 91 109 87 88 89 91 93 96 100 109 118 133
45 47 49 51 55 60 67 79 92 110 88 89 90 91 94 97 101 109 119 133
46 48 50 52 56 61 68 80 92 110 89 90 91 92 95 98 102 110 120 134
47 49 51 53 57 62 69 80 93 110 90 91 92 93 96 98 103 111 120 135
48 50 52 54 58 62 69 81 93 111 91 92 93 94 96 99 104 112 121 135
49 51 53 55 59 63 70 81 94 111 92 93 94 95 97 100 105 113 122 136
50 52 54 56 59 64 71 82 94 112 93 94 95 96 98 101 106 113 123 137
51 53 55 57 60 65 71 83 95 112 94 95 96 97 99 102 106 114 123 137
52 54 56 58 61 66 72 83 95 113 95 96 97 98 100 103 107 115 124 138
53 55 57 59 62 66 73 84 96 113 96 97 98 99 101 104 108 116 125 139
54 56 58 60 63 67 74 85 97 114 97 98 99 100 102 105 109 117 126 139
55 57 59 60 64 68 74 85 97 114 98 99 100 101 103 106 110 118 127 140
56 58 59 61 64 69 75 86 98 115 99 100 101 102 104 107 111 118 127 141
57 59 60 62 65 70 76 86 98 115 100 101 102 103 105 108 112 119 128 141

Questions
1. As a simple rule, what can condensate drain lines be sized on?

a| The plant condensate outlet connection ¨
b| The plant steam inlet connection ¨
c| The trap inlet connection with the correct sized trap ¨
d| It is unimportant to size drain lines correctly ¨
2. For steam mains and constant pressure processes, how is start load estimated?
a| Twice the running load at the rated pressure ¨
b| Three times the running load at a third of the rated pressure ¨
c| Ten times the running load at half the rated pressure ¨
d| The running load at twice the rated pressure ¨
3. On which pressure loss should drain lines be sized?

a| 100 Pa / m ¨
b| They need only be sized on velocity ¨
c| 200 Pa / m ¨
d| 200 Pa / m for lines less than 10 m and 100 Pa / m for lines over 10 m ¨
4. What is the major factor that influences the size of the trap discharge lines?
a| The size of the trap ¨
b| The size of the drain line ¨
c| The amount of flash steam produced in the discharge line ¨
d| The amount of condensate flowing ¨
5. Using Appendix 14.3.1, which size of drain line 1.5 m long should be chosen for a constant
pressure process with a maximum running load of 450 kg / h?
a| 20 mm ¨
b| 32 mm ¨
c| 25 mm ¨
d| 15 mm ¨
6. Three discharge lines 25 mm, 50 mm, 65 mm are to branch into a common line discharging
into a vented receiver. What should be the nominal size of the common line into the
receiver?
a| 100 mm ¨
b| 80 mm ¨
c| 65 mm ¨
d| 50 mm ¨
Answers
1: c, 2: a, 3: d, 4: c, 5: a, 6: a


Block 14 Condensate Recovery Pumping Condensate from Vented Receivers Module 14.4
Module 14.4
Pumping Condensate from
Vented Receivers

Pumping Condensate from Vented Receivers
The justification for returning condensate has already been made and, often, this will entail
lifting condensate by a pump into the boiler feedtank.
Before looking at the types of pump available for returning condensate, it may be helpful to
discuss some basic pumping terminology.
Pumping terminology
Vapour pressure - This term is used to define the pressure corresponding to the temperature at
which a liquid changes into vapour. In other words, it is the pressure at which a liquid will boil.
o At 100°C, water will boil at atmospheric pressure.
o At 170°C, water will boil at a pressure of 7 bar g.
o At 90°C, water will boil at a pressure of 0.7 bar a.
The vapour pressure is a very important consideration when pumping condensate. Condensate
is usually formed at a temperature close to its boiling point, which may cause difficulties where
a centrifugal pump is concerned. This is because centrifugal pumps have an area of lower pressure
at the centre, or eye, of the impeller. This produces the suction effect, which draws the liquid
into the pump. Although the drop in pressure is small, if the condensate is already very close to
its vapour pressure, a proportion of the liquid will flash to steam in the form of small bubbles.
These steam bubbles occupy a significantly greater volume than the equivalent mass of water,
and have a high ratio of surface area to mass.
As the bubbles travel through the impeller passageways towards its outer edge, they experience
increasing pressure. At some point during this journey, the vapour pressure is exceeded, and the
steam bubbles implode with considerable force. This is termed cavitation and the implosions
are both noisy and destructive. The noise is similar to gravel being shovelled and the implosions
will, in time, damage the pump internals.
For this reason, it is recommended that condensate be pumped by electrical pumps specifically
built for the task, and that condensate temperatures in atmospheric systems do not exceed 98°C.
Some pumps will have limits as low as 94°C or 96°C, depending on the design of the pump, the
speed of rotation and the height of the receiver above the pump.
Head (h) - Head is a term used to describe the potential energy of a fluid at a given point. There
are several ways that head can be measured: pressure head, static head and friction head. Pressure
head and static head are essentially the same thing, but tend to be measured in different units.
Pressure head is measured in pressure units such as pascal or bar g; whilst static head is referred
to in terms of height, usually in metres (or metres head).
For water, a static head of 10 metres is approximately equivalent to a pressure head of 1 bar g
(see Figure 14.4.1).
Pressure head (hp) - Pressure head is the fluid pressure at the point in question. For example: A
pump is required to discharge water against a static head of 30 metres, which approximately
equals a pressure head of 3 bar g. The pump fills from a static head of 1 metre, which equals a
pressure head of 0.1 bar g. (See Figure 14.4.2).
Static head (hs) - Static head is the equivalent vertical height of fluid above a datum. The following
example explains the measure of static head. Example: the pump inlet in Figure 14.4.2 is subjected
to a static head (known as the suction or filling head) of 1 m, and discharges against a static head
(known as the static delivery head) of 30 m. Note that in this case, the water being pumped is
above the pump inlet (this situation is called a flooded suction).

10 m
0.1 bar g 1 bar g

1m
Fig. 14.4.1 Pressure of water in terms of head
Collecting tank
Header tank Static delivery

head 30 m
Filling
head
Static suction
head 1 m
Fig. 14.4.2 Suction, delivery, and filling heads
Net static head - This depends upon whether the pump is a centrifugal type pump or a positive
displacement, mechanical type pump.
With an electrical centrifugal pump (Figure 14.4.3), the pressure exerted by the suction head is
always present in the pump. The net static head, against which the pump has to work, is the
difference between the suction head and the delivery head.
Collecting tank
Net static head

29 m
Header tank Static delivery

head 30 m
Static suction
head 1 m
Pump inlet
Fig. 14.4.3 Net static head for an electrical pump

With a mechanical displacement pump (Figure 14.4.4), the suction head only provides the energy
to fill the pump during the filling cycle. It is not present in the pump body during pumping and
has no effect on the delivery head against which the pump has to operate. The net static head is
simply the delivery head.
Collecting tank
Static delivery
Header tank head 30 m
Filling
head
Static suction
head 1 m
Fig. 14.4.4 Net static head for a mechanical pump equals static delivery head
Friction head (hf) - The friction head (or head loss to friction) is more accurately defined as the
energy required to move the fluid through the pipe. This is discussed in further detail in
Module 10.2, Pipes and pipe sizing.
Pressure loss can be calculated using the procedures shown in Block 4, Flowmetering and
Block 10, Steam distribution, but is more usually found from tables that correlate liquid flowrate,
pipe diameter and velocity. To be precise, the resistance to flow encountered by the various
pipeline fittings must also be taken into account. Tables are available to calculate the equivalent
length of straight pipe exerted by various pipe fittings.
This extra equivalent length for pipe fittings is then added to the actual pipe length to give a
total equivalent length. However, in practice, if the pipe is correctly sized, it is unusual for the
pipe fittings to represent more than an additional 10% of the actual pipe length.
A general rule, which can be applied, is:
Total equivalent length (le ) = Actual length + 10%
In most cases, the Steam Plant Engineer will be designing a system with a proprietary manufactured
pump arrangement, which has appropriate factors built in. Bearing this in mind, the figure of
10% will be used in this Block as the equivalent length for calculating pressure loss due to friction.
This pressure loss due to friction is greatly dependent on the velocity of the water in the pipe. In
simple terms, the pressure loss due to friction increases by a factor proportional to the square of
the velocity.
Tables are available which give head loss per metre of pipe for various flowrates and pipe diameters.
Table 14.4.1 Flow of water in black steel pipes (kg / h)
Pressure drop Pipe size (mm)
Pa / m mbar / m 15 20 25 32 40 50 65 80 100
100 1.00 184 425 788 1 724 2 632 5 004 10 152 15 768 31 932
114 1.14 194 450 845 1 832 2 790 5 366 10 841 16 828 34 247
118 1.18 198 457 857 1 890 2 830 5 443 11 022 17 055 34 746

Example 14.4.1
The 50 mm discharge pipework on a pumped condensate line rises vertically for 29 metres to a
vented tank. The line is 150 m long and the pumping rate is 5 000 kg / h of water. What is:
(A) the pressure head loss due to friction (the friction head), and
(B) the total delivery head?
A - Calculate the pressure head loss due to friction (the friction head)
Total equivalent length (le) = 150 + 10 % = 165 metres
From Table 14.4.1, it can be seen that a 50 mm pipe carrying 5 004 kg / h of water will experience
a pressure drop of 1.0 mbar / m. The flowrate in this example is marginally less, and, although a
more accurate estimate could be obtained by interpolation, take the pressure drop as 1 mbar / m.
Pressure head loss due to friction is therefore:
165 metres x 1 mbar / m = 165 mbar (0.165 bar)
Taking 1 bar to be equivalent to 10 metres of water head the equivalent friction head loss in
terms of metres is:
0.165 bar x 10m / bar = 1.65 metres.
B - The total delivery head
Total delivery head (hd) - The total delivery head hd against which the pump needs to operate is
the sum of three components as can be seen in Equation 14.4.1:
7RWDOGHOLYHU\KHDGKG KV KI KS Equation 14.4.1
Where:
hd = Total delivery head
hs = Pressure required to raise the water to the desired level (static head)
hf = Pressure required to move the water through the pipes (friction head)
hp = Pressure in the condensate system (zero in this example as the condensate tank is vented to
atmosphere).
Condensate movement
Total
discharge
head
Total filling
head
Fig. 14.4.5 Net static head for a mechanical pump equals static delivery head
From the information above:

Total delivery head (hd) required = static head + equivalent loss in static head due to friction
hd = 29 m + 1.65 m
hd = 30.65 metre

Electrical centrifugal condensate pumps

Pump operation
Liquid entering the pump is directed into the centre, or eye, of the rotating impeller vanes. The
liquid will then gain velocity as it travels towards the outside of the impeller.
Pump application
The electrical pump is well suited to applications where large volumes of liquid need to be
transported.
Electrical pumps are usually built into a unit, often referred to as a condensate recovery unit
(CRU). A CRU will usually include:
o A receiver.
o A control system operated by probes or floats.
o One or two pumps.
The instantaneous flow from the CRU can be up to 1.5 times greater than the rate at which
condensate returns to the receiver. It is this pumping rate that must be considered when calculating
the friction loss in the discharge line.
On twin pump units, a cascade control system may also be employed which allows either pump
to be selected as the lead pump and the other as a stand-by pump to provide back-up if the
condensate returning to the unit is greater than one pump can handle. This control arrangement
also provides back-up in the case of the one pump failing to operate; the condensate level in the
tank will increase and bring the stand-by pump into operation. Cascade type units usually pump
at a rate of 1.1 times the return rate to the receiver, allowing a smaller discharge line to be
considered.
It is very important to follow the manufacturers literature regarding the discharge pumping rate.
Failure to do so could result in undersizing the pump discharge pipework.
Vent
Condensate inlet
Condensate receiver
Level sensor
Overflow with U seal

Centrifugal
pump
Condensate discharge
Centrifugal
pump
Fig. 14.4.6 A typical electrical condensate recovery unit (CRU)
Sizing an electrical condensate recovery unit

To size an electric condensate recovery unit, it is necessary to know:
o The amount of condensate reaching the receiver at running load.
o The temperature of the condensate. This must not exceed the manufacturers specified ratings
to avoid cavitation, however, manufacturers usually have different impellers to suit different
temperature ranges, for example, 90°C, 94°C and 98°C.
o The total discharge head the pump has to pump against - To be determined from the site conditions.
o The pump discharge rate in order to size the return pipework - It is necessary to read the
manufacturers data properly to determine this.

Example 14.4.2 Sizing discharge pipework for an electric condensate recovery unit
Where:
Temperature of condensate = 94°C
Condensate to be handled = 1 000 kg / h
Static lift (hs) = 30 m
Length of pipework = 150 m
Condensate backpressure = friction losses only (hf)
An initial selection of a condensate recovery unit can be made by using the manufacturers sizing
chart (an example of which is shown in Figure 14.4.7). From the chart, CRU1 should be the
initial choice subject to frictional losses in the delivery pipework.
CRU1
Pump delivery head in metres
CRU2
CRU3
Condensate to be handled at 94°C kg / h

Fig. 14.4.7 A typical electrical condensate recovery unit (CRU) sizing chart (see Example 14.4.2)
From the chart in Figure 14.4.7, it can be seen that CRU1 is actually rated to handle 2 000 kg / h
of condensate against a maximum delivery head of 35 m.
However, on CRUs with pumps that work intermittently, in order to be able to handle the rated
amount of condensate, the pump has to actually move the condensate at some higher flowrate
during the time it is pumping. It is important to know this to be able to size the discharge pipe
correctly.
Consider that the manufacturers data shows that the CRU will actually pump at a rate of
1.5 times the amount of condensate being handled as shown on the sizing chart i.e.:
Actual pumping rate = 1.5 x 2 000 kg / h = 3 000 kg / h
It is this figure, 3 000 kg / h, that must be used to size the discharge pipework.
It is now possible to calculate the optimum size for the return line.
Actual length of pipework = 150 m
Equivalent length of pipework = 150 m + 10% = 165 m

Estimating the friction loss in the pipe (hf)

To size a pumped discharge line it is usually a good idea to begin the friction loss calculation with
an arbitrary pressure drop of between 100 and 200 Pa / m
From the pressure drop Table 14.4.2 (extract shown below), it can be seen that, for a flowrate of
3 000 kg / h, and for a pressure drop of between 100 and 200 Pa/m, a 40 mm discharge pipe will suffice.
Extract from Table 14.4.2
Flowrate kg / h
Pa / m mbar / m <0.15 m / s 0.15 m / s 0.3 m / s
100.0 1.000 184 425 788 1 724 2 632 5 004 10 152 15 768 31 932
120.0 1.200 202 472 871 1 897 2 898 5 508 11 196 17 352 35 100
140.0 1.400 220 511 943 2 059 3 143 5 976 12 132 18 792 38 160
160.0 1.600 234 547 1 015 2 210 3 373 6 408 12 996 20 160 40 680
180.0 1.800 252 583 1 080 2 354 3 589 6 804 13 824 21 420 43 200 1.5
200.0 2.000 266 619 1 141 2 488 3 780 7 200 14 580 22 644 45 720 m / s
It can be interpolated from Table 14.4.2 that a flowrate of 3 000 kg / h will correspond to a
pressure drop of 128 Pa / m, for 40 mm pipework,
The head loss to friction can now be calculated for 40 mm pipework.
Head loss to friction (hf) = 128 Pa / m x 165 m
hf = 21 000 Pa
hf = Approximately 2.1 metres
Establishing the total delivery head
The total delivery head against which the pump has to discharge is therefore h s + h f = h d,
where:
hs = static lift of 30 m (given)
hf = 2.1 metres
hd = 30 m + 2.1 m = 32.1 metres
The delivery head of 32.1 metres needs to be checked against the CRU manufacturers
sizing chart to confirm that the unit can pump against this amount of head. It can be seen
from Figure 14.4.7 that this CRU can actually pump against a 35 metre head. Had the
design head of 35 metres been exceeded, then the options are to re-calculate using a larger
pipe, or to select a CRU with a greater lifting capacity.
An alternative way to size the delivery pipework
With an actual static head (hs) of 30 m, and a CRU design head of 35 m, a 5 m head is available
for pipe friction losses (hf). It might be possible to install a smaller diameter pipe and have a larger
friction loss. However, the designer must weigh this initial cost saving against the extra running
power (and hence cost) required to pump against a larger head.
Velocity also needs to be checked against a typical maximum of about 3 m / s allowable for
pumped water at temperatures below 100°C.
Table 14.4.2 will show that, if the next lower sized pipe (32 mm) were chosen, the unit friction
loss (hf) to pass 3 000 kg / h is interpolated to be 286 Pa / m, and the velocity is about 1 m / s,
which is below 3 m / s and therefore suitable for the application.
hf is 286 Pa / m x 165 m = 47 190 Pa (or 4.72 m)
Therefore, total delivery head (hd) = hs + h f
hd = 30 + 4.72 m
hd = 34.72 m
The conclusion is that a 32 mm pipe could be used, as the CRU1 pump can handle up to 35 m total
delivery head. However, from a practical viewpoint, it might not be reasonable to design a system to
operate so close to its limits, and that, in this instance, 40 mm pipe would probably be the better
solution.

Table 14.4.2 A section of a typical friction loss table for fully flooded pipelines (flowrates in kg / h)
Flowrate kg / h
Pa / m mbar / m <0.15 m / s 0.15 m / s 0.3 m / s
10.0 0.100 50 119 223 490 756 1 447 2 966 4 644 9 432
12.5 0.125 58 133 252 554 853 1 634 3 348 5 220 10 656
15.0 0.150 65 151 277 616 943 1 807 3 708 5 760 11 736
17.5 0.175 68 162 302 670 1 026 1 966 4 032 6 264 12 744
20.0 0.200 76 176 328 720 1 105 2 113 4 320 6 732 13 680
22.5 0.225 79 187 349 770 1 177 2 254 4 608 7 164 14 580 0.5
25.0 0.250 83 198 371 814 1 249 2 387 4 860 7 596 15 408 m/s
27.5 0.275 90 209 389 857 1 314 2 513 5 112 7 992 16 200
30.0 0.300 94 220 410 900 1 379 2 632 5 364 8 352 16 956
32.5 0.325 97 230 428 940 1 440 2 747 5 616 8 712 17 712
35.0 0.350 101 241 446 979 1 498 2 858 5 832 9 072 18 432
37.5 0.375 104 248 464 1 015 1 555 2 966 6 048 9 396 19 116
40.0 0.400 112 259 479 1 051 1 609 3 071 6 264 9 720 19 764
42.5 0.425 115 266 497 1 087 1 663 3 175 6 480 10 044 20 412
45.0 0.450 119 277 511 1 123 1 717 3 272 6 660 10 368 21 024
47.5 0.475 122 284 526 1 156 1 768 3 370 6 876 10 656 21 636
50.0 0.500 126 292 540 1 188 1 814 3 463 7 056 10 944 22 212
52.5 0.525 130 299 558 1 220 1 865 3 553 7 236 11 232 22 788
55.0 0.550 130 306 572 1 249 1 912 3 636 7 416 11 520 23 364
57.5 0.575 133 317 583 1 282 1 958 3 744 7 596 11 808 23 904
60.0 0.600 137 324 598 1 310 2 002 3 816 7 776 12 060 24 444
62.5 0.625 140 331 612 1 339 2 048 3 888 7 920 12 312 24 984
65.0 0.650 144 338 626 1 368 2 092 3 996 8 100 12 600 25 488
67.5 0.675 148 346 637 1 397 2 131 4 068 8 280 12 852 25 992
70.0 0.700 151 353 652 1 422 2 174 4 140 8 424 13 068 26 496
72.5 0.725 151 356 662 1 451 2 218 4 212 8 568 13 320 27 000
75.0 0.750 155 364 677 1 476 2 257 4 284 8 748 13 572 27 468
77.5 0.775 158 371 688 1 505 2 297 4 356 8 892 13 788 27 972
80.0 0.800 162 378 698 1 530 2 336 4 464 9 036 14 040 28 440 1
82.5 0.825 166 385 709 1 555 2 372 4 536 9 180 14 256 28 872 m/s
85.0 0.850 166 389 724 1 580 2 412 4 608 9 324 14 472 29 340
87.5 0.875 169 396 734 1 606 2 448 4 680 9 468 14 724 29 772
90.0 0.900 173 403 745 1 627 2 488 4 716 9 612 14 940 30 240
92.5 0.925 176 407 756 1 652 2 524 4 788 9 756 15 156 30 672
95.0 0.950 176 414 767 1 678 2 560 4 860 9 900 15 372 31 104
97.5 0.975 180 421 778 1 699 2 596 4 932 10 044 15 552 31 500
100.0 1.000 184 425 788 1 724 2 632 5 004 10 152 15 768 31 932
120.0 1.200 202 472 871 1 897 2 898 5 508 11 196 17 352 35 100
140.0 1.400 220 511 943 2 059 3 143 5 976 12 132 18 792 38 160
160.0 1.600 234 547 1 015 2 210 3 373 6 408 12 996 20 160 40 680
180.0 1.800 252 583 1 080 2 354 3 589 6 804 13 824 21 420 43 200 1.5
200.0 2.000 266 619 1 141 2 488 3 780 7 200 14 580 22 644 45 720 m/s
220.0 2.200 281 652 1 202 2 617 3 996 7 560 15 336 23 760 47 880
240.0 2.400 288 680 1 256 2 740 4 176 7 920 16 056 24 876 50 400
260.0 2.600 306 713 1 310 2 855 4 356 8 244 16 740 25 920 52 200
280.0 2.800 317 742 1 364 2 970 4 536 8 568 17 388 26 928 54 360
300.0 3.000 331 767 1 415 3 078 4 680 8 892 18 000 27 900 56 160

Mechanical (positive displacement) condensate pumps

Pump operation
A mechanical pump consists of a body shell, into which condensate flows by gravity. The body
contains a float mechanism, which operates a set of changeover valves.
Condensate is allowed to flow into the body, which raises the float. When the float reaches a
certain level, it triggers a vent valve to close, and an inlet valve to open, to allow steam to enter
and pressurise the body to push out the condensate. The condensate level and the float both fall
to a preset point, at which the steam inlet valve shuts and the vent valve re-opens, allowing the
pump body to refill with condensate.
Check valves are fitted to the pump inlet and discharge ports to ensure correct directional flow
through the pump.
The cyclic action of the pump means that a receiver is required to store condensate while the
pump is discharging (see Figure 14.4.8).
Condensate in Vent Motive steam
Receiver
Condensate
out
Pump
Fig. 14.4.8 A typical mechanical condensate recovery unit (CRU)

Pump application
Generally, mechanical pumps handle smaller amounts of condensate than electrical pumps.
They are however, particularly valuable in situations where:
o High condensate temperatures will cause cavitation in electrical pumps.
o Condensate is in vacuum.
o Plant room space is at a premium.
o Low maintenance is an issue.
o The environment is hazardous, humid or wet.
o Electrical supplies are not at hand.
o Condensate has to be removed from individual items of temperature controlled equipment,
which may be subject to stall conditions (see Block 13 Condensate Removal, for further details).
As with electrically driven pumps, positive displacement mechanical pumps are sometimes, but
not always, specified as packaged condensate recovery units. A mechanical condensate recovery
unit will comprise a condensate receiver and the pump unit. No additional control system is
required as the pump is fully automatic and only operates when needed. This means that the
pump is self-regulating.
With mechanical pumps, the pump cycles as the receiver fills and empties. The instantaneous
flowrate while the pump is discharging can often be up to six times the filling rate and it is this
instantaneous discharge flowrate, which must be used to calculate the size of the discharge pipe.
Always refer to the pump manufacturer for data on sizing the pump and discharge line. A typical
mechanical pump sizing chart is shown in Figure 14.4.10.

Sizing a mechanical condensate pump

To size a mechanical condensate pump, the following information is required:
o The maximum condensate flowrate reaching the receiver.
o The motive pressure of steam or air available to drive the pump. The selection of steam or air
will depend on the application and site circumstances.
o The filling head available between the receiver and pump.
o The total delivery head of the condensate system.
The method of sizing mechanical pumps varies from manufacturer to manufacturer, and is usually
based on empirical data, which are translated into factors and nomographs. The following example
gives a typical method for sizing a mechanical pump. (The pipe length is less than 100 m
consequently friction loss is ignored):
Example 14.4.3 How to size a mechanical condensate pump
Where:
Condensate handling load = 2 100 kg / h
Steam pressure available for operating pump = 5.2 bar g
Vertical lift from pump to return piping = 9.2 m
Pressure in the return piping (piping friction negligible) = 1.7 bar g
Available filling head on the pump = 0.3 m
1.7 bar g
return main
pressure
Condensate
manifold Vent
Total plant 9.2 m lift

condensate
2 100 kg / h
Reservoir
Filling head
* Note: Steam supply to pump not shown * 0.3 m
5.2 bar g
Pump operating
pressure
Fig. 14.4.9 Sizing a mechanical condensate recovery unit (see Example 14.4.3)
Calculate the total backpressure (delivery head hd), against which the condensate must be pumped:
Total backpressure (hd) = lift (hs) + condensate pressure (hp)
Note: The friction loss is neglected because the pipeline is shorter than 100 m.
Condensate lift (hs) = 9.2 m
Condensate pressure (hp) = 1.7 bar g = 17 m head
Total delivery head (hd) = 9.2 m + 17 m
Total delivery head (hd) = 26 m
With reference to the sizing chart shown in Figure 14.4.10: a DN50 pump at 5.2 bar g motive
pressure will pump 2 600 kg / h against a 26 m head. A DN50 pump will thus be an adequate
choice for this example, where the condensate handling load is 2 100 kg / h.

Sizing the discharge pipework for a mechanical condensate pump

The discharge pipe from a mechanical pump can usually be taken to be the same size as the
pump outlet when it is below 100 m long. The frictional resistance of the pipe is relatively small
compared to the backpressure caused by the lift and condensate return pressure, and can usually
be disregarded. For discharge pipes longer than 100 m, the general rule would be to select one
pipe size larger than the pump outlet check valve, but for such longer lines, the size should be
checked as shown in Example 14.4.4
Delivery lines longer than 100 metres
On delivery lines over 100 m, and / or where the condensate flow is near the pump capacity, it is
advisable to check the pipe size to ensure that the total friction loss (including inertia loss) does
not exceed the pumps capability. Inertia loss is explained in Example 14.4.4
Consider the same condensate pumping requirement as in Example 14.4.3 but with a delivery
line 250 metres long.
Example 14.4.4 Sizing a delivery line 250 m long (refer to Figure 14.4.10):
For a DN50 pump, with 5.2 bar g motive steam and 26 m delivery head, the maximum pump
capacity = 2 600 kg / h.
From Figure 14.4.10, the following can be determined:
The actual condensate flowrate into pump = 2 100 kg / h.
Maximum backpressure permissible at 2 100 kg / h = 32 m
Therefore, maximum frictional resistance allowable = 32 - 26 m
Maximum frictional resistance allowable = 6 m (approximately 60 000 Pa)
32 26 metres lift
14
50 m lift
40 m lift
30 m lift
20 m lift
10 m lift
80 m lift
4 m lift
13
12
11
Example 14.4.4
Example 14.4.3
10
9
Motive pressure bar g
5.2
5
0
1 000 2 000 3 000 4 000 5 000
2 100 2 600
DN50 size capacities kg / h Note: The pump is sized on the filling rate
Fig. 14.4.10 Mechanical condensate recovery unit sizing chart - DN50 pump

The effect of inertia loss on pump delivery lines longer than 100 metres.
On lines over 100 m, a considerable volume of liquid will be held within the pump discharge
pipe. The sudden acceleration of this mass of liquid at the start of the pump discharge can
absorb some part of the pump energy and result in a large amount of waterhammer and noise.
This needs to be considered within the calculation by reducing the allowable friction loss of
60 000 Pa in Example 14.4.4 by 50%, thus:
Total allowable friction loss = 50% × 60 000 Pa = 30 000 Pa
Consider delivery pipe length to be 250 m + 10% for additional fittings = 275 m
3D
Consequently, maximum frictional resistance allowable / metre =
P
Maximum frictional resistance » 109 Pa / m
For this type of pump the delivery flowrate is taken as 6 times the filling rate = 6 × 2 100 kg / h
Therefore, the delivery rate of condensate from the pump = 12 600 kg / h
Total allowable friction loss
With a frictional resistance of 109 Pa / m, Table 14.4.2 reveals that an 80 mm pipe (minimum) is
required to give an acceptable flowrate of 12600 kg / h. In fact, Table 14.4.2 indicates that an
80 mm pipe will pass 16 480 kg / h with a frictional resistance of 109 Pa / m.
By rising up the 80 mm column in the table, it can be seen that, by interpolation, the flowrate
of 12 600 kg / h actually induces a frictional loss of 65 Pa / m in an 80 mm pipe.
Fully loaded pumps and longer lines
In Example 14.4.4, Figure 14.4.10 shows that the maximum pump filling rate with a motive
pressure of 5.2 bar g and a delivery head of 26 metres is 2 600 kg /h. Had the filling rate been
close to this maximum, (perhaps 2 500 kg / h), then less delivery head would have been available
for friction loss. For the same size DN50 pump, this would mean a larger delivery pipeline as
shown in Example 14.4.5

Example 14.4.5 Consider the same DN50 pump as described in Example 14.4.4, but
having a condensate filling rate of 2 500 kg / h. Now determine the size of the delivery
pipeline.
27 metres lift
14
50 m lift
40 m lift
30 m lift
20 m lift
10 m lift
80 m lift
4 m lift
13
12
11
10
9
5.2
5
0
1 000 2 000 2 500 3 000 4 000 5 000
DN50 size capacities kg / h
Fig. 14.4.11 Mechanical condensate recovery unit sizing chart (DN50 pump)
Sizing on a filling rate of 2 500 kg / h, and a steam pressure of 5.2 bar, referring to Figure 14.4.11,
for the DN50 pump, it can be seen that a condensate filling rate of 2 500 kg / h equates to a
maximum backpressure of about 27 m, so in this instance:
With an actual delivery head of 26 m:
Available head left for friction losses = 27 - 26 m
Available head left for friction losses = 1 m
The conversion tables in the Engineering Support Centre reveal that a head of 1 metre is equivalent
to 9 806.65 Pa.
For an equivalent length line of 275 m:
3D
The frictional resistance allowable =
P
= 35.7 Pa / m
Minus allowance of 50% for inertia loss = 50% × 35.7 Pa / m
Maximum frictional resistance allowable = 18 Pa / m
As before, the discharge pipework has to be sized on the instantaneous flowrate from the pump
outlet, which is taken as 6 × the filling rate. In this instance, the pipe would have been sized on
6 × 2 500 kg / h = 15 000 kg / h with a friction loss of 18 Pa / m.
Table 14.4.2 shows that this would require a pipe larger than 100 mm (actually 125 mm) to allow
the pump to operate within its capability.
Although the system would certainly work with this arrangement, it is probably more economical
to consider a larger pump in conjunction with a smaller pipeline.

Considerations of a larger pump and smaller pipeline

Consider the same pumping conditions as Example 14.4.4, but with a larger DN80 pump. As a
larger unit can pump against a higher delivery head, a smaller delivery line can be used
35 m 26 m
14
50 m lift
40 m lift
30 m lift
20 m lift
10 m lift
80 m lift
13
12
11
10
9
4 m lift
5.2
5
0
1 000 2 000 3 000 4 000 5 000 6 000
2 500
DN80 x DN50 size capacities kg / h
Fig. 14.4.12 Mechanical condensate recovery unit sizing chart (DN80 pump)
Figure 14.4.12 shows that a DN80 pump under the same conditions of 5.2 bar g motive steam
and 2 500 kg / h flowrate would allow a maximum delivery head of 35 m.
From Example 14.4.4, the actual delivery head = 26 m
At a filling rate of 2 500 kg / h, maximum allowed = 35 m
Head available for friction loss = 35 m - 26 m = 9 metres
The conversion tables in the Engineering Support Centre reveal that a head of 9 m is equivalent
to 88 259.9 Pa.
3D
Therefore 88 259.9 Pa over 275 m and including inertia loss = 50% ×
P
Maximum frictional resistance allowable = 160 Pa / m
The delivery pipe is again sized to carry 6 x 2 500 kg / h = 15 000 kg / h of condensate. By
interpolation, Table 14.4.2 shows that an 80 mm pipe will accommodate 20 160 kg / h with a
friction loss of 160 Pa / m, flowing at about 1 m / s.
In this instance, the larger DN80 pump will comfortably allow a pipe two sizes smaller than that
for the smaller pump, and with a velocity of about 1 m / s, which is within recommendations. The
80 mm pipe is therefore suitable for the DN80 pump.
Note: The DN80 pump would cost about 10% more than the DN50 pump, but the extra cost
would be justified by the difference in installation costs on long delivery lines; which in this
instance would mean the difference in cost between a 80 mm and 125 mm pipe; installation,
fittings, and insulation.

Condensate velocities
Equation 14.4.2 can be used to check the condensate velocity.
&RQGHQVDWHYHORFLW\PV
&RQGHQVDWHIORZUDWHNJ K[&RQGHQVDWHVSHFLILFYROXPHP NJ Equation 14.4.2
SLSHERUH [ PP ] [

NJ K[P NJ
&RQGHQVDWHYHORFLW\PV
PP [
In Equation 14.4.2, the specific volume of water is taken to be 0.001 m3 / kg. This value varies
slightly with temperature but not enough to make any significant difference on condensate lines.
The condensate velocity can be checked for the 80 mm pipework in Example 14.4.4.
The pumping rate = 15 000 kg / h
Condensate specific volume = 0.001 m³ / kg
Pipe bore = 80 mm
[
&RQGHQVDWHYHORFLW\
[
Condensate velocity = 0.83 m / s
From Table 14.4.3 the maximum velocity for an 80 mm bore pipe is 1.8 m / s.
Table 14.4.3 Maximum recommended velocities for pipe bores (based on a maximum friction loss of 450 Pa/ m)
Pipe bore, mm 15 20 25 32 40 50 65 80 100
Velocity, m/s 0.62 0.8 1.0 1.23 1.27 1.5 1.8 1.84 2.4
Best practice for long delivery lines

The momentum of the moving contents of a long delivery line may keep the water in motion for
some time after a mechanical pump has completed its discharge stroke.
When the water in the discharge pipe comes to rest, the backpressure in the line will attempt to
reverse the initial flow of water, back towards the outlet check valve. The result is noise and pipe
movement due to waterhammer, which can be both alarming and serious. Installing another
check valve in the discharge pipe one pipe length from the pump will usually alleviate the problem.
Line over 100 m
Mechanical pump Additional check valve

1 pipe length from pump
Fig. 14.4.13 An additional check valve 1 pipe length from the pump body to reduce
the effect of backflow

If there is any choice, it is always best to lift immediately after the pump to a height allowing a
gravity fall to the end of the line (Figure 14.4.14). If the fall is enough to overcome the frictional
resistance of the pipe (Table 14.4.4), then the only backpressure onto the pump is that formed
by the initial lift. A vacuum breaker can be installed at the top of the lift not only to assist the flow
along the falling line but also to prevent any tendency for backflow at the end of the stroke.
Should the falling line have to fall anywhere along its length to overcome an obstruction, then an
automatic air vent fitted at the highest point will reduce air locking and assist flow around the
obstruction, see Figure 14.4.14.
Automatic air vent
Vacuum breaker
fall
fall due to
obstruction
Mechanical pump
Fig. 14.4.14 Best choice - lift after the pump
Table 14.4.4 Pipefall to overcome frictional losses

Pipefall needed Pipe size (DN mm)
to overcome 15 20 25 32 40 50 65 80 100 125 150
pipe friction Litres of water per hour
25 mm in 15 m 48 140 303 580 907 1 950 3 538 5 806 12 610 22 906 37 284
25 mm in 10 m 59 177 381 694 1 134 2 449 4 445 7 257 15 680 28 576 46 492
25 mm in 8 m 69 204 442 800 1 310 2 834 5 148 8 391 18 159 33 089 53 862
25 mm in 6 m 79 231 503 907 1 487 3 220 5 851 9 525 20 638 37 602 61 223
25 mm in 5 m 86 256 553 1 007 1 642 3 551 6 441 10 568 22 770 41 821 67 538
25 mm in 4 m 93 279 598 1 093 1 778 3 878 7 030 11 521 24 811 45 994 73 571
25 mm in 3 m 113 338 730 1 329 2 168 4 672 8 527 13 925 30 073 54 073 89 356
25 mm in 2 m 140 419 907 1 655 2 694 5 851 10 614 17 327 37 421 68 039 111 128
25 mm in 1.75 m* 152 454 984 1 793 2 923 6 327 11 498 18 756 40 573 73 708 120 426
25 mm in 1.5 m 165 490 1 061 1 932 3 152 6 804 12 383 20 185 43 726 79 378 129 725
25 mm in 1 m 206 612 1 324 2 404 3 923 8 482 15 422 25 174 54 431 99 019 161 476
*A fall of 25 mm in 1.75 m is equivalent to a fall of 1:70.

Alternatively, any question of backpressure caused by the horizontal run can be entirely eliminated
by an arrangement as in Figure 14.4.15 in which the pump simply lifts into a vented break tank.
The pipe from the tank should fall in accordance with Table 14.4.4.
Vent
Break tank
Condensate
Mechanical pump
Condensate
Fig. 14.4.15 Alternative choice - lift after the pump to a break tank
Vented pumps, pumping traps and pump-trap installations

Discharge lines from pumps vented to atmosphere are sized on the discharge rate of the pump.
Condensate passing through pumping traps and pump-trap combinations in closed loop
applications will often be at higher pressures and temperatures and flash steam will be formed in
the discharge line.
Because of this, discharge lines from pumping traps and pump-trap combinations are sized on
the trapping condition at full-load and not the pumping condition, as the line has to be sized to
cater for flash steam. Sizing on flash steam will ensure the line is also able to cope with the
pumping condition.

Questions
1. For pumping condensate, what is the total delivery head?

a| Pressure required to raise the condensate to the required level ¨
b| Pressure required to move the condensate through the pipes ¨
c| Pressure in the condensate system ¨
2. What is the important factor to consider when sizing a pump discharge line?
a| The pump filling rate ¨
b| The pump discharge rate ¨
c| The size of the pump discharge connection ¨
d| The size of the pump inlet connection ¨
3. For a mechanical pump, what is the net static head?

a| The static delivery head ¨
b| The static delivery head less the filling head ¨
c| The static delivery head less the static suction head ¨
4. As a general rule, what equivalent length is added to pipe length to account for pipe
fittings?
a| 5% ¨
b| 10% ¨
c| 15% ¨
d| 20% ¨
5. What is a good arbitrary pressure drop to choose to initially size a pumped delivery line?
a| 10 to 20 Pa / m ¨
b| 50 to 100 Pa / m ¨
c| 500 to 1 000 Pa / m ¨
d| 100 to 200 Pa / m ¨
6. In Figure 14.4.7, what is the maximum capacity of a CRU3 pumping unit against a
15 metre delivery head?
a| 2 000 kg / h ¨
b| 100 kg / h ¨
c| 500 kg / h ¨
d| 1 400 kg / h ¨
Answers
1: d, 2: b, 3: a, 4:b, 5: d, 6: d


Block 14 Condensate Recovery Lifting Condensate and Contaminated Condensate Module 14.5
Module 14.5
Lifting Condensate and
Contaminated Condensate

Lifting Condensate and

Contaminated Condensate
Lifting condensate from a steam main
It is sometimes necessary to lift condensate from a steam trap to a higher level condensate return
line (Figure 14.5.1). The condensate will rise up the lifting pipework when the steam pressure
upstream of the trap is higher than the pressure downstream of the trap.
The pressure downstream of the trap is generally called backpressure, and is made up of any
pressure existing in the condensate line plus the static lift caused by condensate in the rising
pipework. The upstream pressure will vary between start-up conditions, when it is at its lowest,
and running conditions, when it is at its highest.
Backpressure is related to lift by using the following approximate conversion:
1 metre lift in pipework = 1 m head static pressure @ 0.1 bar backpressure
If a head of 5 m produces a backpressure of 0.5 bar, then this reduces the differential pressure
available to push condensate through the trap; although under running conditions the reduction
in trap capacity is likely to be significant only where low upstream pressures are used.
In steam mains at start-up, the steam pressure is likely to be very low, and it is common for water
to back-up before the trap, which can lead to waterhammer in the space being drained. To
alleviate this problem at start-up, a liquid expansion trap, fitted as shown in Figure 14.5.1, will
discharge any cold condensate formed at this time to waste.
As the steam main is warmed, the condensate temperature rises, causing the liquid expansion
trap to close. At the same time, the steam pressure rises, forcing the hot condensate through the
working drain trap to the return line.
High level condensate return
Steam flow Steam main
Trap
Liquid expansion trap
Drain to waste
Fig. 14.5.1 Use of a liquid expansion trap
The discharge line from the trap to the overhead return line, preferably discharges into the top of
the main rather than simply feed to the underside, as shown in Figure 14.5.1. This assists operation,
because although the riser is probably full of water at start-up, it sometimes contains little more
than flash steam once hot condensate under pressure passes through. If the discharge line were
fitted to the bottom of the return line, it would fill with condensate after each discharge and
increase the tendency for waterhammer and noise.

It is also recommended that a check valve be fitted after any steam trap from where condensate
is lifted, preventing condensate from falling back towards the trap.
The above general recommendations apply not just to traps lifting condensate from steam mains,
but also to traps draining any type of process running at a constant steam pressure.
Temperature controlled processes will often run with low steam pressures. Rising condensate
discharge lines should be avoided at all costs, unless automatic pump-traps are used.
Contaminated condensate
Occasionally, condensate is discharged from sources where it might have become contaminated
by corrosive process liquids. This is unsuitable for boiler feedwater because of the dangers of
foaming, scaling, and corrosion which it can cause in the boiler and distribution pipes.
However, although contaminated, the condensate still carries the same useful heat as clean
condensate which could be recovered if proper contamination detection equipment were
employed.
Such equipment detects changes in condensate conductivity. When a change from the desired
conductivity occurs then this may mean that the condensate is contaminated. A controller signals
a dump valve to open, allowing the condensate to flow to drain.
In some countries, continuous monitoring of condensate is a legal requirement.
Controller
Dump valve
Check valve creating a small resistance

to promote flow through the sensor
Condensate in
Condensate out
Sensor
Contaminated
condensate
to waste
Drain
Fig. 14.5.2 Condensate contamination detection equipment

Questions
1. Approximately how much backpressure will 15 m head of water produce?

a| 0.15 bar ¨
b| 1.5 bar ¨
c| 15 bar ¨
d| 15 000 Pa ¨
2. What type of steam trap can assist in draining steam mains at start-up?
a| Thermodynamic type ¨
b| Float-thermostatic type ¨
c| Thermostatic type ¨
d| Liquid expansion type ¨
3. Why is it sensible to dump contaminated condensate?

a| It can corrode steam boilers and distribution pipework ¨
b| It can cause scale in steam boilers and distribution pipework ¨
c| It can cause the boiler water to foam and create carryover ¨
4. Why is it good practice to run a trap discharge line into the top of any condensate
return main?
a| It is cheaper ¨
b| It removes the backpressure ¨
c| It helps to keep the rising line free of residual condensate ¨
d| It removes the static lift ¨
Answers
1: b 2: d, 3: d, 4: c

Block 14 Condensate Recovery Flash Steam Module 14.6
Module 14.6
Flash Steam

Flash Steam
The formation of flash has already been discussed in Module 2.2, What is steam, and a major
flash steam application has been covered in Module 3.13, Heat recovery from boiler blowdown.
This Module will provide a brief reminder of these earlier Modules; discuss how flash steam is
formed, and focus on how flash steam can be used effectively to improve steam plant efficiency.
What is flash steam and why should it be used?

Flash steam is released from hot condensate when its pressure is reduced. Even water at an
ambient room temperature of 20°C would boil if its pressure were lowered far enough. It may be
worth noting that water at 170°C will boil at any pressure below 6.9 bar g. The steam released by
the flashing process is as useful as steam released from a steam boiler.
As an example, when steam is taken from a boiler and the boiler pressure drops, some of the water
content of the boiler will flash off to supplement the live steam produced by the heat from the
boiler fuel. Because both types of steam are produced in the boiler, it is impossible to differentiate
between them. Only when flashing takes place at relatively low pressure, such as at the discharge
side of steam traps, is the term flash steam widely used. Unfortunately, this usage has led to the
erroneous conclusion that flash steam is in some way less valuable than so-called live steam.
In any steam system seeking to maximise efficiency, flash steam will be separated from the
condensate, and used to supplement any low pressure heating application. Every kilogram of
flash steam used in this way is a kilogram of steam that does not need to be supplied by the
boiler. It is also a kilogram of steam not vented to atmosphere, from where it would otherwise be
lost.
The reasons for the recovery of flash steam are just as compelling, both economically and
environmentally, as the reasons for recovering condensate.
How much flash steam is available?
If use is to be made of flash steam, it is helpful to know how much of it will be available. The
quantity is readily determined by calculation, or can be read from simple tables or charts.
Example 14.6.1 - Consider the jacketed vessel shown in Figure 14.6.1
The condensate enters the steam trap as saturated water, at a gauge pressure of 7 bar g and a
temperature of 170°C. The specific amount of heat in the condensate at this pressure is 721 kJ / kg.
After passing through the steam trap, the pressure in the condensate return line is 0 bar g. At this
pressure, the maximum amount of heat each kilogram of condensate can hold is 419 kJ and the
maximum temperature is 100°C. There is an excess of 302 kJ of heat which evaporates some of
the condensate into steam. The quantity of steam is calculated in the following text.
Ball valve
Air vent
Constant pressure Condensate at 7 bar g

steam at 7 bar g hf = 721 kJ / kg
Condensate at 0 bar g
hf = 419 kJ / kg
Steam at 7 bar g
Excess heat at 0 bar g

= 721 - 419 kJ / kg
= 302 kJ / kg
Fig. 14.6.1 Excess heat in condensate produces flash steam

The heat needed to produce 1 kg of saturated steam from water at the same temperature, at
0 bar gauge, is 2 257 kJ. An amount of 302 kJ can therefore evaporate:
N-
NJRIVWHDPSHUNJRIFRQGHQVDWH
N-
From each kilogram of condensate in this example, the proportion of flash steam generated
therefore equals 13.4% of the initial mass of condensate.
If the equipment using steam at 7 bar g were condensing 250 kg / h, then the amount of flash
steam released by the condensate at 0 bar g would be:
0.134 x 250 kg / h of condensate = 33.5 kg / h of flash steam
Alternatively, the chart in Figure 14.6.2 can be read directly for the moderate and low pressures
encountered in many plants.
The example shown in Figure 14.6.1 is depicted in Figure 14.6.2 and shows that 0.134 kg of
flash steam is produced per kg of condensate passing through the trap.
15
14
ar g
ar g
ar g
ar g
ar g
rg
13
0 ba
2.0 b
2.5 b
1 .0 b
1 .5 b
0 .5 b
12
11
10
9
Pressure on traps bar g
0
0 0.02 0.06 0.10 0.14 0.18 0.22
0.134 (See Example 14.6.1)
kg Flash per kg condensate
Fig. 14.6.2 Flash steam graph

Sub-cooled condensate
If the steam trap is of a thermostatic type, the discharged condensate is sub-cooled below saturation
temperature. The heat in the cooler condensate will be slightly less, and the amount of flash
steam produced would be less.
If the trap in Example 14.6.1 discharged condensate at 15°C below the steam saturation
temperature, then the available heat in the condensate would be less.
Example 14.6.2 Consider condensate discharging at 7 bar g and with 15°C of subcooling
Temperature of saturated condensate at 7 bar g = 170°C
Amount of sub cooling = 15°C
Temperature of sub-cooled condensate at 7 bar g = 155°C
From steam tables:
Amount of heat in condensate at 155°C = 654 kJ / kg
At 0 bar g, saturated condensate can only hold = 419 kJ / kg
Surplus heat in saturated condensate at 0 bar g = 235 kJ / kg
Heat in steam at 0 bar g = 2 257 kJ / kg
N- NJ
Proportion of flash steam
N- NJ
Proportion of flash steam from the condensate = 0.104 (10.4%)
Therefore, in this example, condensate discharging at a temperature lower than the saturation
temperature has reduced the proportion of flash steam from 13.4% to 10.4%.
Pressurised condensate
Example 14.6.3 Consider the condensate in Example 14.6.1 discharging to a flash vessel
pressurised at 1 bar g
If the return line were connected to a vessel at a pressure of 1 bar g, then it could be seen
from steam tables that the maximum heat in the condensate at the trap discharge would be
505 kJ / kg and the enthalpy of evaporation at 1 bar g would be 2 201 kJ / kg.
The proportion of the condensate flashing off at 1 bar g can then be calculated as follows:
Heat in condensate at 7 bar g = 721 kJ / kg
At 1 bar g saturated condensate can only hold = 505 kJ / kg
Surplus heat in saturated condensate at 1 bar g = 216 kJ / kg
Heat in steam at 1 bar g = 2 201 kJ / kg
N- NJ
Proportion of flash steam
N- NJ
Proportion of flash steam from the condensate = 0.098 (9.8%)
In this example, if the equipment using steam at 7 bar g were condensing 250 kg / h of steam,
then the amount of flash steam released by the condensate at 1 bar g would be
0.098 x 250 kg / h = 24.5 kg / h of flash steam.
Therefore, the amount of flash steam produced can depend on the type of steam trap used, the
steam pressure before the trap, and the condensate pressure after the trap.

The flash steam recovery vessel (flash vessel)

Flash vessels are used to separate flash steam from condensate. Figure 14.6.3 shows a
typical flash vessel constructed in compliance with the European Pressure Equipment
Directive 97/23/EC.
After condensate and flash steam enter the flash vessel, the condensate falls by gravity to the
base of the vessel, from where it is drained, via a float trap, usually to a vented receiver from
where it can be pumped. The flash steam in the vessel is piped from the top of the vessel to any
appropriate low pressure steam equipment.
Flash steam out
Condensate in
Condensate out
Fig. 14.6.3 A typical flash vessel constructed to European standards
Sizing flash steam recovery vessels

To size a flash vessel, the following information is required:
o The steam pressure before the steam trap(s) supplying the vessel.
o The total condensate flowrate into the flash vessel.
o The flash steam pressure in the flash vessel.
Using this information, together with a flash vessel sizing chart (see Figure 14.6.4), the size of the
vessel can be determined. Example 14.6.4 demonstrates flash vessel sizing, using a chart.

Example 14.6.4 Determine the size of a flash vessel to suit the following conditions:
The pressure onto the steam traps is 12 bar g with a total condensate flow of 2 500 kg / h. The
flash steam from the vessel is to be supplied to equipment using low pressure steam at 1 bar g.
Method:
1. From the Pressure on steam traps axis at 12 bar g, move horizontally to the 1 bar g flash
steam pressure curve at point A.
2. Drop down vertically to the condensate flowrate level of 2 500 kg / h, point B, and follow the
curved line to point C.
3. Move right from point C to meet the 1 bar g flash line at point D.
4. Move upwards to the flash vessel size and select the vessel.
For this example, an FV8 flash vessel would be selected.
7 65 4 3 2 1
20
0.5
18
0.2
Pressure on steam traps bar g
16
0
14
12 A Example
10
8 Flash vessel size

6
FV
FV
FV
FV
FV
6
15
18
8
12
4
0 2 4 6 8 10 12 14 16 18 20%
0

0.2
250 0.5
300 1
400 1.5
Condensate or blowdown flowrate kg /h
500 2
3
4
1 000 5
7
C D
2 000
B
3 000
4 000
5 000
10 000
15 000
20 000
30 000
Fig. 14.6.4 Flash vessel sizing chart
Requirements for successful flash steam applications

If full use is to be made of flash steam, some basic requirements must be satisfied:
o It is essential to have a continual supply of sufficient condensate from applications operating
at higher pressures, to ensure that enough flash steam can be released for economic recovery.
o The steam traps and the equipment they are draining must be able to function satisfactorily
against the backpressure applied by the flash system.

o Care must be taken when attempting flash steam recovery with condensate from temperature
controlled equipment. At less than full-load, the steam space pressure will be lowered by
the closing action of the steam control valve. If the steam pressure in the equipment approaches
or falls below the specified flash steam pressure, the overall amount of flash steam formed
will be marginal, and one must question whether recovery is worthwhile in this instance.
o It is important that there is a demand for low pressure flash steam that either equals or exceeds
the flash steam being produced. Any deficit of flash steam can be made up by live steam from
a pressure reducing valve. If the supply of flash steam exceeds its demand, surplus pressure
will be created in the flash steam distribution system, which will then have to be vented to
waste through a surplussing valve.
o It is possible to utilise the flash steam from condensate on a space heating installation - but
savings will only be achieved during the heating season. When heating is not required, the
recovery system becomes ineffective. Wherever possible, the best arrangement is to use
flash steam from process condensate to supply process loads - and flash steam from heating
condensate to supply heating loads. Supply and demand are then more likely to remain in-step.
o It is preferable to actually use the flash steam close to the high pressure condensate source.
Relatively large diameter pipes are used for low pressure steam, to reduce pressure loss and
velocity, which can mean costly installation if the flash steam has to be piped any distance.
Control of flash steam pressure
Another consideration is a method of controlling the pressure of the flash steam.
In some cases, flash pressure will find its own level and nothing more needs to be done. When
supply and demand are always in-step, and particularly if the low pressure steam is used on the
same equipment producing the high pressure condensate, it is only neccessary to pipe the flash
steam to the low pressure plant without any other control.
Figure 14.6.5 shows the application of flash steam recovery to a multi-bank air heater battery,
which is supplying high temperature air to a process. Condensate from the high pressure sections
is taken to the flash vessel, from where the low pressure flash steam is used, to preheat the cold
air entering the battery via the frost coil (preheater). The surface area of the preheater section,
and the relatively low temperature of the incoming air, will mean that the low pressure flash
steam is readily condensed.
Temperature control valve
High pressure steam supply
Flash steam
Air flow
High
pressure
traps
Flash vessel bypass line
Flash vessel
Low pressure
condensate
Fig. 14.6.5 Flash steam recovery on a multi-bank air heater battery

Depending on operating temperatures, the flash steam will condense at some low pressure,
perhaps even sub-atmospheric. If site conditions and layout permit, the flash vessel and the
steam trap draining the preheater should be located far enough below the preheater condensate
outlet to give enough hydrostatic head to push the condensate through the trap. If this is not
possible, pumping traps can be used to drain both the preheater coil and the flash vessel.
Steam condensing in the preheater at sub-atmospheric pressure will generally mean that a vacuum
breaker is required on the flash steam supply to the preheater. This will prevent the pressure in
the battery becoming sub-atmospheric, thereby assisting condensate flow to the trap. Drainage
from the preheater trap is induced by gravity flow.
Figure 14.6.6 shows an application where the flash steam system is kept at a specified constant
pressure by steam fed from a reducing valve. This ensures a reliable source of steam to the low
pressure system if there is a lack of flash steam to meet the load.
Typical applications for flash steam

Flash steam supply and demand in-step
This gives maximum utilisation of the available flash steam. The air heater battery discussed in
Figure 14.6.5 is one such system, but similar arrangements are practical with many other
applications such as space heating installations using either radiant panels, or unit heaters.
Figure 14.6.6 depicts a system where a number of heaters are supplied with high pressure steam.
The condensate from approximately 90% of the heaters is collected and taken to a flash recovery
vessel. This supplies low pressure steam to the remaining 10% of the heaters.
With this system, the total heat output of the system is marginally reduced, as 10% of the heaters
are operating at a lower steam pressure. However, it is rare to find an installation that does not
have a sufficient margin of output above the normal load to accept this small reduction.
Sometimes a problem arises where the use of available flash steam may require more than one
heater but less than two. It would be better in this case to connect two heaters to the flash steam
supply, rather than vent the excess flash steam off to waste. Two heaters together will usually pull
the flash pressure down to a lower level, even to sub-atmospheric levels. To cope with this, the
supply of flash steam can be supplemented with live steam from a pressure reducing valve.
Pressure reducing valve set
High High pressure heaters Low pressure heaters

pressure
steam
supply
Low
High pressure
pressure traps
traps
Flash vessel
Flash vessel bypass line
Low
pressure
Trap set condensate
Fig. 14.6.6 Flash steam supply and demand in step
Another example where supply and demand are in step is the steam heated hot water storage
calorifier. Some of these incorporate a second coil, fitted close to the bottom of the vessel adjacent
to where the cold feedwater enters.
Condensate and flash steam from the trap on the primary coil is passed directly to the secondary
coil. Here, any flash steam produced by the drop in pressure across the trap is condensed, while
giving up its heat to the feedwater. A typical arrangement is shown in Figure 14.6.7.

Hot water out
Steam
Primary coil trapset

Primary coil
Secondary coil acting

as a flash cooler
Return water in
Low temperature condensate
Fig. 14.6.7 Secondary flash steam coil in a storage calorifier
Another example of this idea is shown in Figure 14.6.8. Here, a normal steam-to-water calorifier
drains condensate through a float trap to a smaller shell-and-tube heat exchanger (called a flash
condenser), in which the flash steam is condensed to sub-cooled condensate. The unit is fitted
such that the secondary flow pipework is in series with both calorifier and condenser. This enables
the secondary return water to be preheated by the condenser, thereby reducing the demand for
live steam in the first instance.
If the condensate in the flash condenser is likely to be sub-atmospheric, a mechanical pump is
required to lift the condensate to any higher return line. The motive steam exhausting from the
pump is itself condensed in the flash condenser. The pumping of the condensate is then achieved
at virtually no cost.
Consideration must be given to the pump filling head in that it needs to be greater than the
pressure drop across the flash condenser tubes under full-load conditions. A minimum head of
600 mm will usually achieve this.
Secondary flow
Steam
Heating calorifier
Temperature control
Steam trap Secondary
flow path
Shell-and-tube heat
* Balance line Air vent exchanger (flash condenser)
*
Receiver Secondary return
Condensate return
Filling head > 600 mm
Motive
steam
Pump
Fig. 14.6.8 Packaged calorifier and flash condenser unit

Flash steam supply and demand not in-step

The arrangement in Figure 14.6.9 is an example of flash steam recovery where the supply and
demand are not always in-step.
Condensate from three jacketed pans and a drain pocket releases flash steam, but it can only be
used to augment the supply of steam to the space heating installation. This is quite satisfactory
during the heating season, as long as the heating load exceeds the availability of flash steam.
During the summer season the heating equipment will not be in use, and even during spring and
autumn the heating load may not be able to use all the available flash steam. The arrangement is
not ideal, although it is quite possible for the steam savings made during the winter to justify the
cost of the flash steam recovery equipment.
Sometimes, surplus flash steam must be vented to atmosphere, and, as indicated, a surplussing
valve is more suitable for this purpose than a safety valve, which usually has a pop or on / off
action and a seat arrangement designed for infrequent operation. The surplussing valve will be
set so that it begins to open slightly above the normal pressure in the system. When the heating
load falls and the pressure in the system begins to increase, the pressure reducing valve supplying
the make-up steam closes down. A further increase of pressure, perhaps of 0.15 to 0.2 bar, is
then allowed before the surplussing valve begins to open to release the excess flash steam.
A safety valve may still be required if the surplussing valve fails. It must be set to open at a
pressure between the surplussing valve set pressure and the system design pressure. It is usually
convenient to fit the safety valve onto the flash vessel.
Occasionally, during summer conditions it may be preferable to bypass the flash system with a
manual valve (not shown in Figure 14.6.9). The condensate and its associated flash steam will
then pass directly to a condensate receiver, where the flash steam will be vented to atmosphere.
Pressure reducing Surplussing

valve Low valve
pressure
steam
Steam
Condensate Flash steam
Medium
pressure
steam
Condensate
Condensate
Flash
Condensate vessel
Condensate
Fig. 14.6.9 Flash steam supply and demand not in-step

Boiler blowdown heat recovery applications

Continuous blowdown of boiler water is necessary to control the level of TDS (Total Dissolved
Solids) within the boiler. Continuous blowdown lends itself to the recovery of the heat content of
the blowdown water and can enable considerable savings to be made.
Boiler blowdown contains massive quantities of heat, which can easily be recovered as flash
steam. After it passes through the blowdown control valve, the lower pressure water flows to a
flash vessel. At this point, the flash steam is free from contamination and is separated from the
condensate, and can be used to heat the boiler feedtank (see Figure 14.6.10).
The residual condensate draining from the flash vessel can be passed through a plate heat
exchanger in order to reclaim as much heat as possible before it is dumped to waste. Up to 80%
of the total heat contained in boiler continuous bowdown can be reclaimed in this way.
Cold Level
water Make-up tank controller
Condensate
Boiler feedtank
Steam
supply to
injector
Flash vessel
Steam
Blowdown
Float trap valve Boiler
Heat
exchanger
Feedpump
Drain
Fig. 14.6.10 Typical heat recovery from boiler blowdown

Spray condensing
Finally, consideration should be given to those cases where flash steam is unavoidably generated
at low pressure, but where no suitable load is available which can make use of it.
Rather than simply discharge the flash steam to waste, the arrangement in Figure 14.6.11 can
often be adopted.
This arrangement can be useful where the condensate receiver vent cannot be piped to outside,
and where the presence of flash steam would be detrimental if left to discharge in a plant room.
A lightweight stainless steel chamber is fitted to the receiver tank vent. Cold water is sprayed into
the chamber in sufficient quantities to just condense the flash steam. The flow of cooling water is
controlled by a simple self-acting temperature control, adjusted so that minimal amounts of flash
steam appear from the vent. The process will use roughly 6 kilograms of cooling water per
kilogram of flash steam condensed.
If the cooling water is of boiler feed quality, then the warmed water is added to the condensate
in the receiver and re-used. This will continue to make water savings throughout the year.
If the cooling water is not suitable for recovery, the spray pipework can be installed as shown by
the dotted arrangement. The cooling water and condensed flash will then fall to waste.
Vented to atmosphere
Water in
Self-acting
temperature Alternative
control arrangement
Condensate
Condensate receiver
Condensed water
to waste
Overflow with U seal
Pumped condensate
Centrifugal pump
Fig 14.6.11 Flash steam condensing and water saving by spray

Questions
1. What is the difference between live steam and flash steam?

a| Live steam is made from water, flash steam is made from condensate ¨
b| Live steam is always hotter than flash steam ¨
c| Live steam is made by adding heat to water, flash steam is made from heat already
contained in water ¨
d| Live steam is always at a higher pressure than flash steam ¨
2. What percentage of flash steam is made from condensate at 10 bar g passing into a flash
vessel at 0.5 bar g?
a| 12% ¨
b| 13% ¨
c| 14% ¨
d| 5% ¨
3. What is the effect on the production of flash steam from sub-saturated condensate?
a| The flash steam produced is less than that with saturated condensate ¨
b| The flash steam produced is more than that with saturated condensate ¨
c| There is no effect at all ¨
d| Live steam is always at a higher pressure than flash steam ¨
4. With reference to Example 14.6.1, what would be the proportion of flash steam produced
if the flash pressure were 2.5 bar g?
a| 3% ¨
b| 6% ¨
c| 8% ¨
d| 10% ¨
5. In a steam system, the trap pressure is 15 bar g, the flash pressure is 0.5 bar g, and the
condensate flowrate is 1300 kg / h. Which flash vessel is required?
a| FV6 ¨
b| FV8 ¨
c| FV12 ¨
d| FV16 ¨
6. What is used to top-up the flash pressure?

a| A safety valve ¨
b| A larger condensate flow ¨
c| A pressure surplussing valve ¨
d| A pressure reducing valve ¨
Answers
1: c 2: c, 3: a, 4: b, 5: b, 6: d


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Block 14 Condensate Recovery Introduction to Condensate Recovery Module 14.

The Steam and Condensate Loop 14.1.1

Introduction to Condensate Recovery

1 kg steam Condensate 1 kg condensate

Fig. 14.1.1 1 kg of steam condenses completely to 1 kg of condensate

14.1.2 The Steam and Condensate Loop

Example 14.1.1 Calculating the amount of flash steam from condensate

The Steam and Condensate Loop 14.1.3

Pan Pan Space

Why return condensate and reuse it?

14.1.4 The Steam and Condensate Loop

The Steam and Condensate Loop 14.1.5

Determine the annual value of returning the condensate

4 PFS ∆7 Equation 2.1.4

Annual fuel cost = 33 106 GJ / year x £2.77 / GJ = £91 704

Part 2 - Determine the water cost

Part 3 - Determine the effluent cost

14.1.6 The Steam and Condensate Loop

Part 4 - Total value of condensate

The Steam and Condensate Loop 14.1.7

Savings in water costs can be determined using Equation 14.1.2:

Savings in effluent costs can be determined using Equation 14.1.3:

Part 1 - Determine the fuel savings

14.1.8 The Steam and Condensate Loop

Part 2 - Determine the water and effluent savings

Substituting values into Equation 14.1.2:

Substituting values into Equation 14.1.3:

6DYLQJVLQHIIOXHQWFRVWV \HDU  [ [   [  P

Part 3 - Determine the payback period

The Steam and Condensate Loop 14.1.9

1. When 10 kg of steam condenses at 0 bar g, how much condensate is produced?

4. If, in Question 3, it is proposed that 50% of the wasted condensate is to be returned

14.1.10 The Steam and Condensate Loop

The Steam and Condensate Loop 14.2.1

Layout of Condensate Return Lines

Drain line to trap Discharge line from trap

Common return line

Type of condensate line Condensate line is sized to carry the folllowing:

14.2.2 The Steam and Condensate Loop

Drain lines to steam traps

+HDWORDG N: [ VK

The Steam and Condensate Loop 14.2.3

 FS ∆7 Equation 2.6.5

 8$∆7 Equation 2.5.3

The surface area of 15 mm pipe = 0.067 m2 / m

14.2.4 The Steam and Condensate Loop

The Steam and Condensate Loop 14.2.5

Air heater battery

D Steam main Steam

Float trap Check valve

Main diameter D Pocket diameter d1 Pocket depth d2

14.2.6 The Steam and Condensate Loop

Discharge lines from traps

Discharging into flooded return lines

Common return lines

Steam Steam main

Common return line

The Steam and Condensate Loop 14.2.7

Continuous discharge traps

Steam Steam main

Fig. 14.2.7 Float trap with a diffuser into a flooded line

Thermostatic trap set with cooling leg

14.2.8 The Steam and Condensate Loop

6DYLQJVLQHIIOXHQWFRVWV \HDU  [ [  [ P

+HDWORDGN:[VK

FS ∆7 Equation 2.6.5

8$∆7 Equation 2.5.3

KI DW3 KI DW3