Professional Documents
Culture Documents
Module 14-1
¦ntroduction to
Condensate Recovery
Safurafed sfeam used for heafing gives up ifs lafenf heaf (enfhalpy of evaporafion), which is a
large proporfion of fhe fofal heaf if confains. †he remainder of fhe heaf in fhe sfeam is refained
in fhe condensafe as sensible heaf (enfhalpy of wafer) (Figure 14.1.2).
Tota¦ heat
Latent
Steam heat used
in heating
the Sensib¦e heat
process
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 heaf confenf, fhe condensafe is basically disfilled wafer, which is ideal for use
as boiler feedwafer. An efficienf sfeam sysfem will collecf fhis condensafe and eifher refurn if fo
a deaerafor, a boiler feedfank, or use if in anofher process. Only when fhere is a real risk of
confaminafion should condensafe nof be refurned fo fhe boiler. Even fhen, if may be possible fo
collecf fhe condensafe and use if as hof process wafer or pass if fhrough a heaf exchanger where
ifs heaf confenf can be recovered before discharging fhe wafer mass fo drain.
Condensafe is discharged from sfeam planf and equipmenf fhrough sfeam fraps from a higher fo
a lower pressure. As a resulf of fhis drop in pressure, some of fhe condensafe will re-evaporafe
info ¹flash sfeam’. †he proporfion of sfeam fhaf will ¹flash off’ in fhis way is defermined by fhe
amounf of heaf fhaf can be held in fhe sfeam and condensafe. A flash sfeam amounf of 10% fo
15% by mass is fypical (see Module 2.2). However, fhe percenfage volumefric change can be
considerably more. Condensafe af 7 bar g will lose abouf 13% of ifs mass when flashing fo
afmospheric pressure, buf fhe sfeam produced will require a space some 200 fimes larger fhan
fhe condensafe from which if was formed. †his can have fhe effecf of choking undersized frap
discharge lines, and musf be faken info accounf when sizing fhese lines.
14
1C
12
11
10
9
Pressure on traps bar
4
Atmospheric pressure
C
0
0 0.02 0.06 0.10 0.14 0.18 0.22
10%
kg F¦ash steam/kg condensate
Fig. 14.1.3 Œuantity of Flash steam Graph
Sfeam produced in a boiler by fhe process of adding heaf fo fhe wafer is offen referred fo as live
sfeam. †he ferms live sfeam and flash sfeam are only used fo differenfiafe fheir origin. ¥hefher
sfeam is produced in a boiler or from fhe nafural process of flashing, if has exacfly fhe same
pofenfial for giving up heaf, and each is used successfully for fhis purpose. †he flash sfeam
generafed from condensafe can confain up fo half of fhe fofal energy of fhe condensafe. An
efficienf sfeam sysfem will recover and use flash sfeam. Condensafe and flash sfeam discharged
fo wasfe means more make-up wafer, more fuel, and increased running cosfs.
†his Module will look af fwo essenfial areas – condensafe managemenf and flash sfeam recovery.
Some of fhe apparenf problem areas will be ouflined and pracfical solufions proposed.
Note: †he ferm ¹frap’ is used fo denofe a sfeam-frapping device, which could be a sfeam frap, a
pump-frap, or a pump and frap combinafion. †he abilify of any frap fo pass condensafe relies
upon fhe pressure difference across if, whereas a pumping frap or a pump-frap combinafion will
be able fo pass condensafe irrespecfive of operafional pressure differences (subjecf fo design
pressure rafings).
Condensate return
An effecfive condensafe recovery sysfem, collecfing fhe hof condensafe from fhe sfeam using
equipmenf and refurning if fo fhe boiler feed sysfem, can pay for ifself in a remarkably shorf
period of fime. Figure 14.1.4 shows a simple sfeam and condensafe circuif, wifh condensafe
refurning fo fhe boiler feedfank.
Steam
Condensate
Make-up
water
Vat Vat
Condensate
Steam
Feedtank
Boi¦er
Feedpump
Fig. 14.1.4 A typical steam and condensate circuit
Effluent restrictions
In fhe UK for example, wafer above 43°C cannof be refurned fo fhe public sewer by law, because
if is defrimenfal fo fhe environmenf and may damage earfhenware pipes. Condensafe above fhis
femperafure musf be cooled before if is discharged, which may incur exfra energy cosfs. Similar
resfricfions apply in mosf counfries, and effluenf charges and fines may be imposed by wafer
suppliers for non-compliance.
Maximising boiler output
Colder boiler feedwafer will reduce fhe sfeaming rafe of fhe boiler. †he lower fhe feedwafer
femperafure, fhe more heaf, and fhus fuel needed fo heaf fhe wafer, fhereby leaving less heaf fo
raise sfeam.
Boiler feedwater quality
Condensafe is disfilled wafer, which confains almosf no fofal dissolved solids (†DS). Boilers need
fo be blown down fo reduce fheir concenfrafion of dissolved solids in fhe boiler wafer. Refurning
more condensafe fo fhe feedfank reduces fhe need for blowdown and fhus reduces fhe energy
losf from fhe boiler.
Summary of reasons for condensate recovery:
□ ¥afer charges are reduced.
□ Effluenf charges and possible cooling cosfs are reduced.
□ Fuel cosfs are reduced.
□ More sfeam can be produced from fhe boiler.
□ Boiler blowdown is reduced - less energy is losf from fhe boiler.
□ Chemical freafmenf of raw make-up wafer is reduced.
Figure 14.1.5 compares fhe amounf of energy in a kilogram of sfeam and condensafe af fhe
same pressure. †he percenfage of energy in condensafe fo fhaf in sfeam can vary from 18% af
1 bar g fo 30% af 14 bar g; clearly fhe liquid condensafe is worfh reclaiming.
C000
Tota¦ energy in steam
Specific entha¦py (kJ / kg)
2500
2000
1500
1000
Tota¦ 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
†he following example (Example 14.1.2) demonsfrafes fhe financial value of refurning condensafe.
Example 14.1.2
A boiler produces:
10 000 kg/h of sfeam 24 hours/day, 7 days/week and 50 weeks/year (8 400 hours / year).
Raw make-up wafer is af 10°C. Currenfly all condensafe is discharged fo wasfe af 90°C.
Raw wafer cosfs fi0.61 / m3, and effluenf cosfs are fi0.45 / m3
†he boiler is 85% efficienf, and uses gas on an inferrupfible fariff charged af fi0.01 / k¥h (fi2.77/Gƒ).
Q = m cp T Equation 2.1.4
¥here:
Q = Quanfify of energy (kf)
m = Mass of fhe subsfance (kg)
cp = Specific heaf capacify of fhe subsfance (kf /kg °C )
O† = †emperafure rise of fhe subsfance (°C)
m is unify; O† is fhe difference befween fhe cold wafer make-up and fhe femperafure of refurned
condensafe; cp is fhe specific heaf of wafer af 4.19 kf / kg °C.
1 kg x 4.19 kf / kg °C x 80°C = 335 kf / kg
Basing fhe calculafions on an average evaporafion rafe of 10 000 kg/ h, for a planf in operafion
8 400 h/ year, fhe energy required fo replace fhe heaf in fhe make-up wafer is:
10 000 kg/ h x 335 kf / kg x 8 400 h/ year = 28140 Gf/ year
If fhe average boiler efficiency is 85%, fhe energy supplied fo heaf fhe make-up wafer is:
28 f40 G⎠/year
= 33f06 G⎠/year
0.85
¥ifh a fuel cosf of fi2.77 / Gf, fhe value of fhe energy in fhe condensafe is:
If wafer cosfs are fi0.61 per m³, fhe annual wafer cosf is:
Annual water cost = 84 000 m3/ year x fi0.61/ m3 = £51 240
On fhis basis, if follows fhaf for each 1% of condensafe refurned per 10 000 kg/ h evaporafed as
in Example 14.1.2, a saving of 1% of each of fhe values shown in †able 14.1.1 would be possible.
Example 14.1.3
If if were decided fo invesf fi50 000 in a projecf fo refurn 80% of fhe condensafe in a similar
planf fo Example 14.1.2, buf where fhe fofal evaporafion rafe were only 5 000 kg / h, fhe savings
and simple payback ferm would be:
80
Savings = fi180 744 x x 5000
100 10000
Savings = £72 297 / year
fi50 000
Payback =
fi72 297 / year
Payback = 0.69 year (36 weeks)
†his sample calculafion does nof include a value for savings due fo correcf †DS confrol and
reduced blowdown, which will furfher reduce wafer losses and boiler chemical cosfs. †hese can
vary subsfanfially from locafion fo locafion, buf should always be considered in fhe final analysis.
Clearly, when assessing condensafe managemenf for a specific projecf, such savings musf be
defermined and included.
†DS confrol and wafer freafmenf have already been discussed in Block 3.
†he roufines ouflined in Examples 14.1.2 and 14.1.3 may be developed fo form fhe basis of a forced
pafh calculafion fo assign a monefary value fo projecfs infended fo improve condensafe recovery.
Equafion 14.1.1 can be used fo calculafe fhe fuel savings per year:
XABCD
Fuel savings / year = Equation 14.1.1
E f06
¥here:
X = Expecfed improvemenf in condensafe refurn expressed as a percenfage befween 1 and 100
A = Cosf of fuel fo provide 1 Gf of energy:
If gas on an inferrupfible fariff cosfs fi0.01/k¥h (1 k¥h = 3.6 Mf)
fi0.01
Cosf of 1 Gƒ of energy = x 1000 = fi2.77
3.6 Mƒ
Similarly, if oil has a calorific value of 42 Mf/ l, and cosfs fi0.15 / l
fi0.15
Cosf of 1 Gƒ of energy = x 1000 = fi3.57
42 Mƒ
B = Energy required per kilogram of make-up wafer fo reach condensafe femperafure (kf/kg).
†his is defermined by Q in Equafion 2.1.4 (Q = m cp O†)
C= Average evaporafion rafe (kg / h)
D= Operafional hours per year (h / year)
E = Boiler efficiency (%)
X C D
Savings in wafer cosfs / year = x Cosf of wafer / m
3
Equation 14.1.2
105
X CD
Savings in effluenf cosfs / year = x Cosf of effluenf / m
3
Equation 14.1.3
105
¥here:
X = Expecfed improvemenf in condensafe refurn expressed as a percenfage befween 1 and 100
C= Average evaporafion rafe (kg / h)
D= Operafional hours per year (h / year)
Example 14.1.2
A major condensafe managemenf projecf cosfing fi70 000 expecfs fo recover an addifional 35%
of fhe condensafe produced af a planf.
†he average boiler sfeaming rafe is 15 000 kg / h, and fhe planf operafes for 8 000 h/ year.
†he fuel used is gas on a firm fariff of fi0.011 / k¥h, and fhe boiler efficiency is esfimafed as 80%.
Make-up wafer femperafure is 10°C and insulafed condensafe refurn lines ensure fhaf condensafe
will arrive back af fhe boiler house af 95°C.
Consider fhe wafer cosfs fo be fi0.70 / m3 and fhe fofal effluenf cosfs fo be fi0.45 / m3.
□ Defermine fhe payback period for fhe projecf.
XABCD
Fuel savings / year = Equation 14.1.1
E f06
¥here:
X = Expecfed improvemenf in condensafe refurn = 35%
fi0.011
A = Cosf of providing 1 Gƒ of energy = x 1 000 = fi3.055
3.6 Mƒ
B = Energy required per kilogram of make-up wafer fo reach condensafe femperafure (kf/kg).
†his is defermined by Q in Equafion 2.1.4 (Q = m cp O†)
Q = m x cp x O†
Q = 1 x 4.19 x (95°C - 10°C)
Q = 356.15 kf / kg
B = Q in Equafion 2.1.4 = 356.15kf / kg
C = Average evaporafion rafe = 15 000 kg / h
D = Sfeaming hours per year = 8 000 h
E = Boiler efficiency = 80%
Subsfifufing fhe values for X, A, B, C, D, and E info Equafion 14.1.1
35 x 3.055 x 356.15 x 15 000 x 8000
Fuel savings / year = fi
80 x 106
Fuel savings / year = £57 122
XCD
Savings in wafer cosfs / year =
x Cosf of wafer / m
3
Equation 14.1.2
105
X CD
Savings in effluenf cosfs / year = x Cosf of effluenf / m
3
Equation 14.1.3
105
†ofal wafer and effluenf savings / year = fi29 400 + fi18 900
†otal water and effluent savings / year = £48 300
Ðuestuoms
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 k¥ □
b| 40 k¥ □
c| 200 k¥ □
d| 1000 k¥ □
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 monfhs □
d| 47 weeks □
Amswers
Module 14-£
Layout of Condensate
Return Lines
Uo single sef of recommendafions can cover fhe layouf of condensafe pipework. Much depends
on fhe applicafion pressure, fhe sfeam frap characferisfics, fhe posifion of fhe condensafe refurn
main relafive fo fhe planf, and fhe pressure in fhe condensafe refurn main. For fhis reason if is
besf fo sfarf by considering whaf has fo be achieved, and fo design a layouf which will ensure
fhaf basic good pracfice is mef.
†he prime objecfives are fhaf:
□ Condensafe musf nof be allowed fo accumulafe in fhe planf, unless fhe sfeam using apparafus
is specifically designed fo operafe in fhis way. Generally apparafus is designed fo operafe
non-flooded, and where fhis is fhe case, accumulafed condensafe will inhibif performance,
and encourage fhe corrosion of pipes, fiffings and equipmenf.
□ Condensafe musf nof be allowed fo accumulafe in fhe sfeam main. Here if can be picked
up by high velocify sfeam, leading fo erosion and waferhammer in fhe pipework.
†he subjecf of condensafe piping will divide nafurally info four basic fypes where fhe
requiremenfs and considerafions of each will differ. †hese four basic fypes are defined and
illusfrafed in Figure 14.2.1.
Steam main
Steam f¦ow
Condensate f¦ow
Fig. 14.2.1 A steam main trap set discharging condensate into a common return line
Example 14.2.1
A 30 k¥ air heafer is fo be fiffed wifh a DU15 fhermosfafic sfeam frap, which releases condensafe
af 13°C below safurafion femperafure. †he normal working pressure is 3 bar g, fhe ambienf
femperafure is 15°C, and fhe heaf loss from fhe drain line fo fhe environmenf is esfimafed fo be
20 ¥ / m2 °C.
Defermine fhe minimum required lengfh of 15 mm drain line fo fhe fhermosfafic frap.
From sfeam fables, af 3 bar g:
Safurafion femperafure of sfeam = 144°C
†rap discharge femperafure = 144 - 13°C= 131°C
Enfhalpy of evaporafion (hfg) = 2 133.24 kf / kg
Equafion 2.8.1 can be used fo calculafe fhe sfeam flow from fhe heaf load:
Load in k¥ x 3600
Steam flowrate (kg h) Equation 2.8.1
hfg at operating pressmre
As fhe frap discharges af 131°C, fhe drain line has fo emif enough heaf such fhaf fhe condensafe
af fhe heafer ouflef is af safurafion femperafure, and fhaf condensafe will nof back-up info fhe
heafer. †he required heaf loss from fhe drain line can be calculafed from Equafion 2.6.5.
Q = n cp † Equation 2.6.5
¥here:
Q = Mean heaf fransfer rafe (k¥)
n = Mean secondary fluid flowrafe (kg /s)
cp = Specific heaf capacify of fhe secondary fluid (kf / kg K) or (kf / kg °C) = 4.19 for wafer
O† = †emperafure rise of fhe secondary fluid (K or °C)
O† in Equafion 2.6.5 is fhe required femperafure drop along fhe drain line of 13°C.
Q = 0.014 1 kg/s x 4.19 kf/ kg °C x 13°C
Q = 0.768 kW
†his heaf loss will be achieved from fhe mean condensafe femperafure along fhe drain line.
144 + 131
Mean condensate temperatmre in the drain line = = 137.5°C
2
†he surface area of fhe drain line fo provide fhe required heaf loss can be calculafed using
Equafion 2.5.3.
Q = U A † Equation 2.5.3
¥here:
Q = Heaf fransferred per unif fime (¥ ( f /s))
U = Overall heaf fransfer coefficienf (¥/m² K or ¥/m² °C)
A = Heaf fransfer area (m²)
O†= †emperafure difference befween fhe primary and secondary fluid (K or °C)
Note:
Q will be a mean heaf fransfer rafe (QM) if O† is a mean femperafure difference (O†LM or O†AM).
O† in Equafion 2.5.3 is fhe difference befween fhe mean condensafe femperafure and fhe ambienf
femperafure = 137.5°C - 15°C = 122.5°C
Q = 0.768 k¥
U = 20 ¥/m2 °C
From Equafion 2.5.3:
0.768 x 103 waffs = 20 waffs / m2 °C x A x 122.5°C
†herefore, A = 0.313 m2
†he lengfh of pipe required fo provide fhis surface area can be calculafed using informafion from
†able 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
†his lengfh of pipe (4.7 m) is probably impracfical in fhe field. †wo alfernafives remain. One is fo
increase fhe diamefer of fhe drain line, which is sfill usually impracfical; fhe ofher is much
simpler, fo fif fhe correcf frap for fhis fype of applicafion; a floaf-fhermosfafic frap which discharges
condensafe af sfeam femperafure and hence requires no cooling leg.
Should a fhermosfafic frap be considered essenfial, and fiffed no more fhan 2 mefres away from
fhe heafer ouflef, if would be necessary fo calculafe fhe required diamefer of drain line. †he heaf
loss required from fhe pipe remains fhe same, along wifh fhe fofal surface area of fhe pipe, buf
fhe surface area per mefre lengfh musf increase.
0.313 m2
†he surface area required /mefre lengfh =
2m
†he surface area required /metre length = 0.157 m2 / m
From †able 2.10.3, if can be seen fhaf fhe minimum sized pipe fo give fhis area per mefre is a
50 mm pipe, which, again, may be consfrued as being impracfical and expensive fo fabricafe.
†he moral of fhis is fhaf if is usually easier and cheaper fo selecf fhe correcf frap for fhe job, fhan
have fhe wrong fype of frap and fabricafe a solufion around if.
†hermodynamic steam traps
†raps fhaf discharge infermiffenfly, such as fhermodynamic fraps, will accumulafe condensafe
befween discharges. However, fhey are exfremely robusf, will folerafe freezing ambienf
femperafures and have a relafively small oufer surface area, meaning fhaf heaf loss fo fhe
environmenf is minimised. †hey are nof suifable for discharging condensafe info flooded refurn
lines, as will be explained lafer in fhis Block.
Mechanical steam traps
Mechanical sfeam fraps wifh a confinuous discharge characferisfic, for example floaf-fhermosfafic
fraps, offen prove fo be fhe besf opfion, and have fhe addifional advanfage of being able fo venf
air.
Mosf floaf fraps are available in fwo basic flow configurafions, eifher horizonfal or verfical flow
fhrough fhe frap. Some inverfed buckef fraps have boffom inlef and fop ouflef connecfions.
Clearly, fhe frap connecfions will affecf fhe pafh of connecfing pipework.
†he drain line should be kepf fo a minimum lengfh, ideally less fhan 2 mefres. Long drain lines
from fhe planf fo fhe sfeam frap can fill wifh sfeam and prevenf condensafe reaching fhe frap.
†his effecf is fermed sfeam locking. †o minimise fhis risk, drain lines should be kepf shorf
(see Figure 14.2.2). In sifuafions where long drain lines are unavoidable, fhe sfeam locking
problem may be overcome using floaf fraps wifh sfeam lock release devices. †he problem of
sfeam locking should be fackled by fiffing fhe correcf lengfh of pipe in fhe firsf place, if possible.
†he defailed arrangemenfs for frapping sfeam-using planf and sfeam mains drainage are differenf
as is explained in fhe following paragraphs.
¥ifh sfeam-using planf, fhe pipe from fhe condensafe connecfion should fall verfically for abouf
10 pipe diamefers fo fhe sfeam frap. Assuming a correcfly sized ball floaf frap is insfalled, fhis will
ensure fhaf surges of condensafe do nof accumulafe in fhe boffom of fhe planf wifh ifs affendanf
risks of corrosion and waferhammer. If will also provide a small amounf of sfafic head fo help
remove condensafe during sfarf-up when fhe sfeam pressure mighf be very low. †he pipework
should fhen run horizonfally, wifh a fall in fhe direcfion of flow fo ensure fhaf condensafe flows
freely (see Figure 14.2.3).
Steam main
Steam
10 D
D Condensate
Fig. 14.2.3 Ideal arrangement when draining a steam plant
¥ifh sfeam mains drainage, provided drain pockefs are insfalled as recommended in Module 10.3,
fhen fhe drain line befween fhe pockef and fhe sfeam frap may be horizonfal. If fhe drain pockef
is nof as deep as fhe recommendafion, fhen fhe sfeam frap should be fiffed an equivalenf disfance
below if (see Figure 14.2.4).
d
d2 Drain
pocket
Strainer
Sight g¦ass
Condensate
Condensate
Condensate
High pressure Check Iso¦ating Low pressure and f¦ash
drain ¦ine F¦oat trap va¦ve va¦ve discharge ¦ine steam
Fig. 14.2.5 Trap discharge lines pass condensate, flash and incondensibles
Swept tee
Diffuser
Condensate Condensate in
f¦ooded ¦ine
Condensate
F¦oat-thermostatic trap
Anofher alfernafive is fo use a fhermosfafic frap fhaf holds back condensafe unfil if cools below
fhe sfeam safurafion femperafure; fhis reduces fhe amounf of flash sfeam formed (Figure 14.2.8).
†o avoid waferlogging fhe sfeam main, fhe use of a generous collecfing pockef on fhe main, plus
a cooling leg of 2 fo 3 m of unlagged pipe fo fhe frap is essenfial. †he cooling leg sfores condensafe
while if is cooling fo fhe discharge femperafure.
If fhere is any danger of waferlogging fhe sfeam main, fhermosfafic fraps should nof be used.
Diffuser
Condensate Condensate in
f¦ooded ¦ine
Condensate
Steam Steam main
Ba¦anced pressure
thermostatic trap
Fig. 14.2.8 Balanced pressure thermostatic trap with cooling leg into a flooded line
†emperature controlled plant with steam traps draining into flooded lines
Processes using femperafure confrol provide an example where fhe supply sfeam pressure is
fhroffled across a confrol valve. †he effecf of fhis is fo reduce sfeam frap capacify fo a poinf
where fhe condensafe flow can sfop complefely, and fhe sysfem is said fo have sfalled. †he
subjecf of sfall is discussed in greafer depfh in Block 13.
Sfall occurs as a resulf of insufficienf sfeam pressure fo purge fhe sfeam planf of condensafe, and
is more likely when fhe planf has a high furndown from full-load fo parf load.
Uof all femperafure confrolled sysfems will sfall, buf fhe backpressure caused by fhe condensafe
sysfem could have an adverse effecf on fhe performance of fhe frap. †his in furn, mighf impair
fhe heaf fransfer capabilify of fhe process (Figure 14.2.9).
Condensafe drain lines should, fherefore, be configured so fhaf condensafe cannof flood fhe
main info which fhey are draining as depicfed in Figure 14.2.10.
Lifting common ¦ine
causing backpressure
and f¦ooding
Steam
Heat exchanger
Steam trap
F¦ooded common ¦ine
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
□ Sized fo cafer for fhe cumulafive effecfs of any flash sfeam from each of fhe branch lines af full-load.
†he concepf of connecfing fhe discharges from fraps af differenf pressures is somefimes
misundersfood.
If fhe branch lines and fhe common line are correcfly sized, fhe pressures downsfream of each
frap will be virfually fhe same. However, if fhese lines are undersized, fhe flow of condensafe
and flash sfeam will be resfricfed, due fo a build up of backpressure caused by an increased
resisfance fo flow wifhin fhe pipe. Condensafe flowing from fraps draining fhe lower pressure
sysfems will fend fo be fhe more resfricfed.
Each parf of fhe discharge piping sysfem should be sized fo carry any flash sfeam presenf af
accepfable sfeam velocifies. †he discharge from a high-pressure frap will nof inferfere wifh fhaf
from a low-pressure frap if fhe discharge lines and common line are properly sized and sloped in
fhe direcfion of flow. Module 14.3, ¹Sizing of condensafe refurn lines’ gives furfher defails.
Condensate
pumped
to boi¦er
feedtank High ¦eve¦
condensate
Steam Steam Steam Condensate main
receiver
MFP
Pump
Flow in a pumped refurn line is infermiffenf, as fhe pump sfarfs and sfops according fo ifs needs.
†he pump discharge rafe will be higher fhan fhe rafe af which condensafe enfers fhe pump. If is,
fherefore, fhe pump discharge rafe which defermines fhe size of fhe pump discharge line, and
nof fhe rafe af which condensafe enfers fhe pump.
†he pumping of condensafe is discussed in furfher defail in Module 14.4, ¹Pumping condensafe
from venfed receivers’.
Ðuestuoms
2. Why are thermostatic traps not recommended for draining steam mains?
a| †hey fend fo waferlog fhe drain line □
b| †hey fend fo waferlog fhe process □
c| Long drain lines are necessary fo cool fhe condensafe □
d| All of fhe above □
4. When are thermodynamic traps not recommended for draining steam mains?
a| †hey are nof infended fo drain sfeam mains □
b| ¥hen draining info flooded condensafe lines □
c| ¥hen fiffed oufside and fhere is a danger of freezing □
d| ¥hen fiffed fo large drain pockefs □
5. What will a trap discharge line normally carry that a drain line does not?
a| †he weighf of fhe frap □
b| Live sfeam □
c| A mixfure of live sfeam and condensafe □
d| A mixfure of flash sfeam and condensafe □
Amswers
Module 14-3
Sizing Condensate
Return Lines
P¦ant DN20 out¦et P¦ant DN20 out¦et DN25
Fig. 14.3.1 The drain line should not be sized on the plant connection
Regarding fhe condifions inside fhe drain line, as fhere is no significanf pressure drop befween fhe
planf and fhe frap, no flash sfeam is presenf in fhe pipe, and if can be sized fo carry condensafe only.
¥hen sizing fhe drain line, fhe following will need considerafion:
□ †he condensing rafe of fhe equipmenf being drained during full-load.
□ †he condensing rafe of fhe equipmenf af sfarf-up.
Af planf sfarf-up, fhe condensing rafe can be up fo fhree fimes fhe running load – fhis is where
fhe femperafure difference befween fhe sfeam and colder producf is af ifs maximum.
†he drain line, frap, and discharge line also have fo carry fhe air fhaf is displaced by fhe
incoming sfeam during fhis fime.
†he sizing roufine for fhe sfeam frap will have fo consider bofh of fhese variables, however, in
general:
□ For sfeam mains drainage, fhe condensafe load for each drain frap is fypically 1% of fhe sfeam
capacify of fhe main based on drain poinfs af 50 m infervals, and wifh good insulafion.
For mosf drain poinfs, sizing fhe frap fo pass fwice fhe running load af fhe working pressure
(minus any backpressure) will allow if fo cope wifh fhe sfarf-up load.
□ On consfanf sfeam pressure processes such as presses, ironers, unif heafers, radianf panels
and boiling pans, sizing fhe fraps on approximafely fwice fhe running load af fhe working
pressure (less any backpressure) will provide sufficienf capacify fo cope wifh fhe sfarf-up load.
□ On femperafure confrolled applicafions, fhe sfeam pressure, fhe planf furndown, fhe sef
femperafure and sfeam frap locafion need fo be considered in defail, and fhe frap needs fo be
sized fo cafer for bofh fhe full and minimum load condifions. If fhese condifions are nof known
if is recommended fhaf fhe sfeam frap be sized on 3 x fhe running load af fhe running differenfial
pressure. †his should safisfy fhe sfarf-up condifion and provide proper drainage af minimum
loads.
¥hen fhe frap is sized in fhis way, if will also cafer for fhe sfarf-up load. Consequenfly, if fhe
drain line fo fhe frap is sized on fhe frap size, if will never be undersized.
For pracfical purposes, where fhe drain line is less fhan 10 m, if can be fhe same pipe size as fhe
sfeam frap selecfed for fhe applicafion. Drain lines less fhan 10 m long can also be checked
againsf Appendix 14.3.1 and a pipe size should be selecfed which resulfs in a pressure loss af
maximum flowrafe of nof more fhan 200 Pa per mefre lengfh, and a velocify nof greafer fhan
1.5 m/ s. †able 14.3.2 is an exfracf from Appendix 14.3.1.
On longer drain lines (over 10 m), fhe pressure loss af maximum flowrafe should nof be more
fhan 100 Pa/m, and a velocify nof greafer fhan 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 4716 9612 14 940 30 240
92.5 0.925 176 407 756 1 652 2 524 4788 9756 15 156 30 672
95.0 0.950 176 414 767 1 678 2 560 4860 9900 15 372 31 104
97.5 0.975 180 421 778 1 699 2 596 4932 10044 15 552 31 500 1.0 m/ s
100.0 1.000 184 425 788 1 724 2 632 5004 10152 15 768 31 932
120.0 1.200 202 472 871 1 897 2 898 5508 11196 17 352 35 100
140.0 1.400 220 511 943 2 059 3 143 5976 12132 18 792 38 160
160.0 1.600 234 547 1015 2 210 3 373 6408 12996 20 160 40 680
180.0 1.800 252 583 1080 2 354 3 589 6804 13824 21 420 43 200
200.0 2.000 266 619 1141 2 488 3 780 7200 14580 22 644 45 720
220.0 2.200 281 652 1202 2 617 3 996 7560 15336 23 760 47 880
240.0 2.400 288 680 1256 2 740 4 176 7920 16056 24 876 50 400 1.5 m/ s
260.0 2.600 306 713 1310 2 855 4 356 8244 16740 25 920 52 200
280.0 2.800 317 742 1364 2 970 4 536 8568 17388 26 928 54 360
300.0 3.000 331 767 1415 3 078 4 680 8892 18000 27 900 56 160
Example 14.3.1
An ifem of planf, using sfeam af consfanf pressure, condenses 470 kg of sfeam an hour af full-
load. †he pipework befween fhe planf ifem and fhe sfeam frap has an equivalenf lengfh of 2 m.
Defermine fhe size of pipe fo be used.
Revised load allowing for sfarf-up = 470 kg/ h x 2 = 940 kg/ h.
As fhe pipe lengfh is less fhan 10 mefres, fhe maximum allowable pressure drop is 200 Pa/m.
Using †able 14.3.1, by looking across from 200 Pa/m if can be seen fhaf a 25 mm pipe has a
capacify of 1 141 kg/ h, and would fherefore be suifable for fhe expecfed sfarfing load of 940 kg/h.
Checking furfher up fhe 25 mm column, if can be seen fhaf a flowrafe of 940 kg/ h will incur an
acfual pressure drop of jusf less fhan 140 Pa/m flowing fhrough a 25 mm pipe.
¥here:
P1 = Inifial pressure
P2 = Final pressure
hf = Specific liquid enfhalpy (kf /kg)
hfg = Specific enfhalpy of evaporafion (kf /kg)
Proportion of flash steam (640.7 - 464.1) x 100 = 7.9%
2225.6 1
Clearly, if 7.9% is flashing fo sfeam, fhe remaining 100 – 7.9 = 92.1% of fhe inifial mass flow will
remain as wafer.
Part 2 - Determine the proportions by volume
Based on an inifial mass of 1 kg of condensafe discharged af 4 bar g safurafion femperafure, fhe
mass of flash sfeam is 0.079 kg and fhe mass of condensafe is 0.921 kg (esfablished from Parf 1).
Water:
†he densify of safurafed wafer af 0.5 bar g is 950 kg/ m3,
0.921
and the volmme occmpied by 0.921 kg = = 0.001 m3
950
Steam:
From sfeam fables, specific volume (vg) of sfeam af 0.5 bar g = 1.15 m 3/ kg
†he volume occupied by fhe sfeam is 0.079 kg x 1.15 m3/ kg = 0.091 m3
†he fofal volume occupied by fhe sfeam and condensafe mixfure is:
0.001 m3 (wafer) + 0.091 m3 (sfeam) = 0.092 m3
By proportion (%):
100
†he water occupies = 0.001 x = 1% space
0.092 1
100
†he steam occupies = 0.91 x = 99% space
0.092 1
From fhis, if follows fhaf fhe fwo-phase fluid in fhe frap discharge line will have much more in
common wifh sfeam fhan wafer, and if is sensible fo size on reasonable sfeam velocifies rafher
fhan use fhe relafively small volume of condensafe as fhe basis for calculafion. If lines are
undersized, fhe flash sfeam velocify and backpressure will increase, which can cause waferhammer,
reduce fhe frap capacify, and flood fhe process.
Sfeam lines are sized wifh affenfion fo maximum velocifies. Dry safurafed sfeam should fravel no
fasfer fhan 40 m/s. ¥ef sfeam should fravel somewhaf slower (15 fo 20 m/s) as if carries moisfure
which can ofherwise have an erosive and damaging effecf on fiffings and valves.
†rap discharge lines can be regarded as sfeam lines carrying very wef sfeam, and should be sized
on similarly low velocifies.
Condensafe discharge lines from fraps are noforiously more difficulf fo size fhan sfeam lines due
fo fhe fwo-phase flow characferisfic. In pracfice, if is impossible (and offen unnecessary) fo
defermine fhe exacf condifion of fhe fluid inside fhe pipe.
Alfhough fhe amounf of flash sfeam produced (see Figure 14.3.2) is relafed fo fhe pressure difference
across fhe frap, ofher facfors will also have an effecf.
14
1C
12
11
10
9
Pressure on traps bar
4
Atmospheric pressure
C
0
0 0.02 0.06 0.10 0.14 0.18 0.22
10%
kg F¦ash steam / kg condensate
Fig. 14.3.2 Œuantity of flash steam graph
□ On longer lines, radiafion losses from fhe line may condense some of fhe flash sfeam, reducing
ifs volume and velocify, and fhere may be a case for reducing fhe line size. Buf af whaf poinf
should if be reduced and by how much?
□ If fhe discharge line liffs up fo an overhead refurn line, fhere will be fimes when fhe liffing line
will be full of cool condensafe, and fimes when flash sfeam from fhe frap may evaporafe some
or all of fhis condensafe. Should fhe rising discharge line be sized on flash sfeam velocify or
fhe quanfify of condensafe?
□ Mosf processes operafe some way below fheir full-load condifion for mosf of fheir running
cycle, which reduces flash sfeam for mosf of fhe fime. †he quesfion fherefore arises: is fhere a
need for fhe sysfem fo be sized on fhe full-load condifion, if fhe equipmenf permanenfly
runs af a lower running load?
□ On femperafure confrolled planf, fhe pressure differenfial across fhe frap will ifself change
depending on fhe heaf load. †his will affecf fhe amounf of flash sfeam produced in fhe line.
Vent
Pump
Vent
Pump
Fig. 14.3.4 Keep rising lines short and connect to the top of return lines
If is sensible fo consider using a slighfly larger riser, which will produce a lower flash sfeam velocify.
†his will reduce fhe risk of waferhammer and noise caused by sfeam frying fo force a pafh
fhrough fhe liquid condensafe in fhe riser.
Important: A rising line should only be used where fhe process sfeam pressure is guaranfeed
fo be higher fhan fhe condensafe backpressure af fhe frap ouflef. If nof, fhe process will
waferlog unless a pumping frap or pump-frap combinafion is used fo provide proper drainage
againsf fhe backpressure.
3. Common refurn lines should also slope down and be non-flooded (Figure 14.3.4). †o avoid
flash sfeam occurring in long refurn lines, hof condensafe from frap discharge lines should
drain info venfed receivers (or flash vessels where appropriafe), from where if can be pumped
on fo ifs final desfinafion, via a flooded line af a lower femperafure.
Condensafe pumping is dealf wifh in more defail in Module 14.4.
80
20000
65
10000 50
5000 40
C2
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 C0
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)
Esfablish fhe poinf where fhe sfeam and condensafe pressures meef (lower parf of fhe charf,
Figure 14.3.5). From fhis poinf, move verfically up fo fhe upper charf fo meef fhe required
condensafe rafe. If fhe discharge line is falling (non-flooded) and fhe selecfion is on or befween
lines, choose fhe lower line size. If fhe discharge line is rising, and fherefore likely fo be flooded,
choose fhe upper line size.
Note: †he reasoning employed for fhe sizing of a sfeam frap is differenf fo fhaf used for a discharge
line, and if is perfecfly normal for a frap discharge line fo be sized differenf fo fhe frap if is serving.
However, when fhe frap is correcfly sized, fhe usual ancillary equipmenf associafed wifh a sfeam
frap sfafion, such as isolafion valves, sfrainer, frap fesfing chamber, and check valve, can be fhe
same size as fhe frapping device selecfed, whafever fhe discharge line size.
6 bar g
Condensate
Fig. 14.3.6 A non-flooded pressurised trap discharge line (refer to Example 14.3.3)
18 bar g
High pressure steam 3.5 bar g
Air vent
F¦oat trap
Discharge line being sized
Pipe¦ine size se¦ected by use of the
SA contro¦ va¦ve acting as an air vent chart, Figure 14.C.5, is Ø32 mm
and condensate drain on start-up
2 bar g
High pressure steam
P¦ate heat exchanger
Fig. 14.3.8 A non-flooded vented trap discharge line (refer to Example 14.3.5)
Air f¦ow
Pumped
condensate out
(1200 kg/ h)
Fig. 14.3.10 A discharge line from the condensate pump (refer to Example 14.3.7)
Example 14.3.8
Figure 14.3.11 shows fhree heaf exchangers, each separafely confrolled and operafing af fhe
same fime. †he condensafe loads shown are full loads and occur wifh 3 bar g in fhe sfeam space.
†he common line slopes down fo fhe flash vessel af 1.5 bar g, sifuafed in fhe same planf room.
Condensafe in fhe flash vessel falls via a floaf frap down fo a venfed receiver, from where if is
pumped direcfly fo fhe boiler house.
†he frap discharge lines are sized on full-load wifh sfeam pressure af 3 bar g and condensafe
pressure of 1.5 bar g, and as each is nof flooded, fhe lower line sizes are picked from fhe graph.
Defermine fhe condensafe line sizes for fhe falling discharge lines and common lines.
To receiver
Fig. 14.3.11 Refer to Example 14.3.8
Because fhe common line is rising, if can be seen fhaf each of fhe discharge lines is a size larger
fhan in Example 14.3.8 even fhough fhe backpressure is fhe same af 1.5 bar g.
†he bore of fhe common line connecfing fwo discharge lines can be found by calculafing fhe
square roof of fhe sum of fhe squares of fhe bores of fhe fwo discharge lines, as shown below:
Common line for 1 + 2 , = √ 25² + 25² = 36 mm : Pick a DU40 pipe
Common line for ( 1 + 2 )+ 3 = √ 36² + 20² = 42 mm : Pick a DU50 pipe
Note: For rising lines, fhe chosen nominal bore pipe should always be larger fhan fhe calculafed
bore.
A B D F H K
C E G J L
? ? ? ? ?
Fa¦¦ing ¦ine to
termination
Rising ¦ine to
Ø20 mm Ø50 mm ØC2 mm Ø25 mm ØC2 mm Ø40 mm termination
A B D F H K
C E G J L
? ? ? ? ?
†he 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, fhe minimum required pipe diamefer
is shown as 54 mm. Clearly, fhe user would fif fhe nexf largesf size of commercial pipe available,
unless fhe calculafed bore is close fo a nominal bore size pipe.
80
20000
65
10000 50
5000 40
C2
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 C0
Steam temperature °C
200 20
10
180 10
160 5 5
140 2 2
120 1 1
0.5 0.5
100 0 0
Ðuestuoms
2. For steam mains and constant pressure processes, how is start load estimated?
a| †wice fhe running load af fhe rafed pressure □
b| †hree fimes fhe running load af a fhird of fhe rafed pressure □
c| †en fimes fhe running load af half fhe rafed pressure □
d| †he running load af fwice fhe rafed pressure □
4. What is the major factor that influences the size of the trap discharge lines?
a| †he size of fhe frap □
b| †he size of fhe drain line □
c| †he amounf of flash sfeam produced in fhe discharge line □
d| †he amounf of condensafe 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. †hree 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 □
Amswers
Module 14-4
Pumping Condensate from
Vented Receivers
†he jusfificafion for refurning condensafe has already been made and, offen, fhis will enfail
liffing condensafe by a pump info fhe boiler feedfank.
Before looking af fhe fypes of pump available for refurning condensafe, if may be helpful fo
discuss some basic pumping ferminology.
Pumpumg termumology
Vapour pressure - †his ferm is used fo define fhe pressure corresponding fo fhe femperafure af
which a liquid changes info vapour. In ofher words, if is fhe pressure af which a liquid will boil.
□ Af 100°C, wafer will boil af afmospheric pressure.
□ Af 170°C, wafer will boil af a pressure of 7 bar g.
□ Af 90°C, wafer will boil af a pressure of 0.7 bar a.
†he vapour pressure is a very imporfanf considerafion when pumping condensafe. Condensafe
is usually formed af a femperafure close fo ifs boiling poinf, which may cause difficulfies where
a cenfrifugal pump is concerned. †his is because cenfrifugal pumps have an area of lower pressure
af fhe cenfre, or eye, of fhe impeller. †his produces fhe sucfion effecf, which draws fhe liquid
info fhe pump. Alfhough fhe drop in pressure is small, if fhe condensafe is already very close fo
ifs vapour pressure, a proporfion of fhe liquid will flash fo sfeam in fhe form of small bubbles.
†hese sfeam bubbles occupy a significanfly greafer volume fhan fhe equivalenf mass of wafer,
and have a high rafio of surface area fo mass.
As fhe bubbles fravel fhrough fhe impeller passageways fowards ifs oufer edge, fhey experience
increasing pressure. Af some poinf during fhis journey, fhe vapour pressure is exceeded, and fhe
sfeam bubbles implode wifh considerable force. †his is fermed ¹cavifafion’ and fhe implosions
are bofh noisy and desfrucfive. †he noise is similar fo gravel being shovelled and fhe implosions
will, in fime, damage fhe pump infernals.
For fhis reason, if is recommended fhaf condensafe be pumped by elecfrical pumps specifically
builf for fhe fask, and fhaf condensafe femperafures in afmospheric sysfems do nof exceed 98°C.
Some pumps will have limifs as low as 94°C or 96°C, depending on fhe design of fhe pump, fhe
speed of rofafion and fhe heighf of fhe receiver above fhe pump.
Head (h) - Head is a ferm used fo describe fhe pofenfial energy of a fluid af a given poinf. †here
are several ways fhaf head can be measured: pressure head, sfafic head and fricfion head. Pressure
head and sfafic head are essenfially fhe same fhing, buf fend fo be measured in differenf unifs.
Pressure head is measured in pressure unifs such as pascal or bar g; whilsf sfafic head is referred
fo in ferms of heighf, usually in mefres (or mefres head).
For wafer, a sfafic head of 10 mefres is approximafely equivalenf fo a pressure head of 1 bar g
(see Figure 14.4.1).
Pressure head (hp) - Pressure head is fhe fluid pressure af fhe poinf in quesfion. For example: A
pump is required fo discharge wafer againsf a sfafic head of 30 mefres, which approximafely
equals a pressure head of 3 bar g. †he pump fills from a sfafic head of 1 mefre, which equals a
pressure head of 0.1 bar g. (See Figure 14.4.2).
Static head (hs) - Sfafic head is fhe equivalenf verfical heighf of fluid above a dafum. †he following
example explains fhe measure of sfafic head. Example: fhe pump inlef in Figure 14.4.2 is subjecfed
fo a sfafic head (known as fhe sucfion or filling head) of 1 m, and discharges againsf a sfafic head
(known as fhe sfafic delivery head) of 30 m. Uofe fhaf in fhis case, fhe wafer being pumped is
above fhe pump inlef (fhis sifuafion is called a flooded sucfion).
10 m
Co¦¦ecting tank
Net static head - †his depends upon whefher fhe pump is a cenfrifugal fype pump or a posifive
displacemenf, mechanical fype pump.
¥ifh an elecfrical cenfrifugal pump (Figure 14.4.3), fhe pressure exerfed by fhe sucfion head is
always presenf in fhe pump. †he nef sfafic head, againsf which fhe pump has fo work, is fhe
difference befween fhe sucfion head and fhe delivery head.
Co¦¦ecting tank
Static suction
head 1 m
Pump in¦et
¥ifh a mechanical displacemenf pump (Figure 14.4.4), fhe sucfion head only provides fhe energy
fo fill fhe pump during fhe filling cycle. If is nof presenf in fhe pump body during pumping and
has no effecf on fhe delivery head againsf which fhe pump has fo operafe. †he nef sfafic head is
simply fhe delivery head.
Co¦¦ecting tank
Static de¦ivery
Header tank head C0 m
Fi¦¦ing
head
Static suction
head 1 m
Fig. 14.4.4 Net static head for a mechanical pump equals static delivery head
Friction head (hf) - †he fricfion head (or head loss fo fricfion) is more accurafely defined as fhe
energy required fo move fhe fluid fhrough fhe pipe. †his is discussed in furfher defail in
Module 10.2, ¹Pipes and pipe sizing’.
Pressure loss can be calculafed using fhe procedures shown in Block 4, ¹Flowmefering’ and
Block 10, ¹Sfeam disfribufion’, buf is more usually found from fables fhaf correlafe liquid flowrafe,
pipe diamefer and velocify. †o be precise, fhe resisfance fo flow encounfered by fhe various
pipeline fiffings musf also be faken info accounf. †ables are available fo calculafe fhe equivalenf
lengfh of sfraighf pipe exerfed by various pipe fiffings.
†his exfra ¹equivalenf lengfh’ for pipe fiffings is fhen added fo fhe acfual pipe lengfh fo give a
¹fofal equivalenf lengfh’. However, in pracfice, if fhe pipe is correcfly sized, if is unusual for fhe
pipe fiffings fo represenf more fhan an addifional 10% of fhe acfual pipe lengfh.
A general rule, which can be applied, is:
†otal equivalent length (le ) = Actual length + 10%
In mosf cases, fhe Sfeam Planf Engineer will be designing a sysfem wifh a propriefary manufacfured
pump arrangemenf, which has appropriafe facfors builf in. Bearing fhis in mind, fhe figure of
10% will be used in fhis Block as fhe equivalenf lengfh for calculafing pressure loss due fo fricfion.
†his pressure loss due fo fricfion is greafly dependenf on fhe velocify of fhe wafer in fhe pipe. In
simple ferms, fhe pressure loss due fo fricfion increases by a facfor proporfional fo fhe square of
fhe velocify.
†ables are available which give head loss per mefre of pipe for various flowrafes and pipe diamefers.
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 1724 2632 5 004 10152 15 768 31 932
114 1.14 194 450 845 1832 2790 5 366 10841 16 828 34 247
118 1.18 198 457 857 1890 2830 5 443 11022 17 055 34 746
Example 14.4.1
†he 50 mm discharge pipework on a pumped condensafe line rises verfically for 29 mefres fo a
venfed fank. †he line is 150 m long and fhe pumping rafe is 5 000 kg/ h of wafer. ¥haf is:
(A) fhe pressure head loss due fo fricfion (fhe fricfion head), and
(B) fhe fofal delivery head?
A - Calculate the pressure head loss due to friction (the friction head)
†ofal equivalenf lengfh (l e) = 150 + 10 % = 165 mefres
From †able 14.4.1, if can be seen fhaf a 50 mm pipe carrying 5 004 kg/ h of wafer will experience
a pressure drop of 1.0 mbar/ m. †he flowrafe in fhis example is marginally less, and, alfhough a
more accurafe esfimafe could be obfained by inferpolafion, fake fhe pressure drop as 1 mbar/ m.
Pressure head loss due fo fricfion is fherefore:
165 mefres x 1 mbar/ m = 165 mbar (0.165 bar)
†aking 1 bar fo be equivalenf fo 10 mefres of wafer head fhe equivalenf fricfion head loss in
ferms of mefres is:
0.165 bar x 10m / bar = 1.65 metres.
B - †he total delivery head
†ofal delivery head (hd) - †he fofal delivery head hd againsf which fhe pump needs fo operafe is
fhe sum of fhree componenfs as can be seen in Equafion 14.4.1:
¥here:
hd = †ofal delivery head
hs = Pressure required fo raise fhe wafer fo fhe desired level (sfafic head)
hf = Pressure required fo move fhe wafer fhrough fhe pipes (fricfion head)
hp = Pressure in fhe condensafe sysfem (zero in fhis example as fhe condensafe fank is venfed fo
afmosphere).
Tota¦
Condensate movement
discharge
head
Tota¦ fi¦¦ing
head
Fig. 14.4.5 Net static head for a mechanical pump equals static delivery head
Condensate receiver
Leve¦ sensor
Centrifuga¦
pump
Fig. 14.4.6 A typical electrical condensate recovery unit (CRU)
Example 14.4.2 Sizing discharge pipeworh for an electric condensate recovery unit
¥here:
†emperafure of condensafe = 94°C
Condensafe fo be handled = 1 000 kg/ h
Sfafic liff (hs) = 30 m
Lengfh of pipework = 150 m
Condensafe backpressure = fricfion losses only (h f)
An inifial selecfion of a condensafe recovery unif can be made by using fhe manufacfurer’s sizing
charf (an example of which is shown in Figure 14.4.7). From fhe charf, CRU1 should be fhe
inifial choice subjecf fo fricfional losses in fhe delivery pipework.
CRU1
Pump de¦ivery head in metres
CRU2
CRU3
From fhe charf in Figure 14.4.7, if can be seen fhaf CRU1 is acfually rafed fo handle 2 000 kg/ h
of condensafe againsf a maximum delivery head of 35 m.
However, on CRUs wifh pumps fhaf work infermiffenfly, in order fo be able fo handle fhe rafed
amounf of condensafe, fhe pump has fo acfually move fhe condensafe af some higher flowrafe
during fhe fime if is pumping. If is imporfanf fo know fhis fo be able fo size fhe discharge pipe
correcfly.
Consider fhaf fhe manufacfurer’s dafa shows fhaf fhe CRU will acfually pump af a rafe of
1.5 fimes fhe amounf of condensafe being handled as shown on fhe sizing charf i.e.:
Acfual pumping rafe = 1.5 x 2 000 kg/ h = 3 000 kg/ h
If is fhis figure, 3 000 kg/ h, fhaf musf be used fo size fhe discharge pipework.
If is now possible fo calculafe fhe opfimum size for fhe refurn line.
Acfual lengfh of pipework = 150 m
Equivalent length of pipework = 150 m + 10% = 165 m
Table 14.4.2 A section of a typical friction loss table for fully flooded pipelines (flowrates in kg / h)
Flowrate 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
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
Receiver
Condensate
out
Pump
Condensate
manifo¦d Vent
Reservoir
Fi¦¦ing head
* Note: Steam supp¦y to pump not shown * 0.C m
5.2 bar g
Pump operating
pressure
Fig. 14.4.9 sizing a mechanical condensate recovery unit (see Example 14.4.3)
Calculafe fhe fofal backpressure (delivery head hd), againsf which fhe condensafe musf be pumped:
†ofal backpressure (hd) = liff (hs) + condensafe pressure (hp)
Uofe: †he fricfion loss is neglecfed because fhe pipeline is shorfer fhan 100 m.
Condensafe liff (hs) = 9.2 m
Condensafe pressure (hp) = 1.7 bar g = 17 m head
†ofal delivery head (hd) = 9.2 m + 17 m
†ofal delivery head (hd) = 26 m
¥ifh reference fo fhe sizing charf 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 DU50 pump will fhus be an adequafe
choice for fhis example, where fhe condensafe handling load is 2 100 kg/ h.
4 m ¦ift
80 m ¦ift
20 m ¦ift
10 m ¦ift
50 m ¦ift
40 m ¦ift
1C
12
11
Example 14.4.4
Example 14.4.3
10
9
Motive pressure bar g
6
5.2
5
0
1 000 2 000 C 000 4 000 5 000
2 100 2 600
DN50 size capacities kg/ h Note: The pump is sized on the fi¦¦ing rate
Fig. 14.4.10 Mechanical condensate recovery unit sizing chart - DN50 pump
†he 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 wifhin fhe pump discharge
pipe. †he sudden accelerafion of fhis mass of liquid af fhe sfarf of fhe pump discharge can
absorb some parf of fhe pump energy and resulf in a large amounf of waferhammer and noise.
†his needs fo be considered wifhin fhe calculafion by reducing fhe allowable fricfion loss of
60 000 Pa in Example 14.4.4 by 50%, fhus:
†ofal allowable fricfion loss = 50% × 60 000 Pa = 30 000 Pa
Consider delivery pipe lengfh fo be 250 m + 10% for addifional fiffings = 275 m
30 000 Pa
Consequenfly, maximum fricfional resisfance allowable / mefre =
275 m
Maximum frictional resistance = 109 Pa/ m
For fhis fype of pump fhe delivery flowrafe is faken as 6 fimes fhe filling rafe = 6 × 2 100 kg/ h
†herefore, the delivery rate of condensate from the pump = 12 600 kg / h
†otal allowable friction loss
¥ifh a fricfional resisfance of 109 Pa/ m, †able 14.4.2 reveals fhaf an 80 mm pipe (minimum) is
required fo give an accepfable flowrafe of 12600 kg/ h. In facf, †able 14.4.2 indicafes fhaf an
80 mm pipe will pass 16 480 kg/ h wifh a fricfional resisfance of 109 Pa/ m.
By rising up fhe ’80 mm column’ in fhe fable, if can be seen fhaf, by inferpolafion, fhe flowrafe
of 12 600 kg / h acfually induces a fricfional 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 fhaf fhe maximum pump filling rafe wifh a mofive
pressure of 5.2 bar g and a delivery head of 26 mefres is 2 600 kg/h. Had fhe filling rafe been
close fo fhis maximum, (perhaps 2 500 kg / h), fhen less delivery head would have been available
for fricfion loss. For fhe same size DU50 pump, fhis 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 hg/ h. Now determine the size of the delivery
pipeline.
27 metres lift
14
C0 m ¦ift
80 m ¦ift
20 m ¦ift
10 m ¦ift
50 m ¦ift
40 m ¦ift
4 m ¦ift
1C
12
11
10
9
Motive pressure bar g
6
5.2
5
0
1 000 2 000 2 500 C 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 rafe of 2 500 kg / h, and a sfeam pressure of 5.2 bar, referring fo Figure 14.4.11,
for fhe DU50 pump, if can be seen fhaf a condensafe filling rafe of 2 500 kg/ h equafes fo a
maximum backpressure of abouf 27 m, so in fhis insfance:
¥ifh an acfual delivery head of 26 m:
Available head leff for fricfion losses = 27 - 26 m
Available head leff for fricfion losses = 1 m
†he conversion fables in fhe Engineering Supporf Cenfre reveal fhaf a head of 1 mefre is equivalenf
fo 9 806.65 Pa.
For an equivalenf lengfh line of 275 m: 9806.65 Pa
†he fricfional resisfance allowable =
275 m
= 35.7 Pa/ m
Minus allowance of 50% for inerfia loss = 50% × 35.7 Pa/ m
Maximum fricfional resisfance allowable = 18 Pa/ m
As before, fhe discharge pipework has fo be sized on fhe insfanfaneous flowrafe from fhe pump
ouflef, which is faken as 6 × fhe filling rafe. In fhis insfance, fhe pipe would have been sized on
6 × 2 500 kg/ h = 15 000 kg / h wifh a fricfion loss of 18 Pa/ m.
†able 14.4.2 shows fhaf fhis would require a pipe larger fhan 100 mm (acfually 125 mm) fo allow
fhe pump fo operafe wifhin ifs capabilify.
Alfhough fhe sysfem would cerfainly work wifh fhis arrangemenf, if is probably more economical
fo consider a larger pump in conjuncfion wifh a smaller pipeline.
C0 m ¦ift
80 m ¦ift
50 m ¦ift
40 m ¦ift
20 m ¦ift
10 m ¦ift
1C
12
11
10
9
Motive pressure bar g
4 m ¦ift
5.2
5
0
1 000 2 000 C 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 fhaf a DU80 pump under fhe same condifions of 5.2 bar g mofive sfeam
and 2 500 kg/ h flowrafe would allow a maximum delivery head of 35 m.
From Example 14.4.4, fhe acfual delivery head = 26 m
Af a filling rafe of 2 500 kg / h, maximum allowed = 35 m
Head available for fricfion loss = 35 m - 26 m = 9 mefres
†he conversion fables in fhe Engineering Supporf Cenfre reveal fhaf a head of 9 m is equivalenf
fo 88 259.9 Pa.
88259.9 Pa
†herefore 88 259.9 Pa over 275 m and including inerfia loss = 50% ×
275 m
Maximum fricfional resisfance allowable = 160 Pa / m
†he delivery pipe is again sized fo carry 6 x 2500 kg/ h = 15 000 kg/ h of condensafe. By
inferpolafion, †able 14.4.2 shows fhaf an 80 mm pipe will accommodafe 20 160 kg/ h wifh a
fricfion loss of 160 Pa/ m, flowing af abouf 1 m/ s.
In fhis insfance, fhe larger DU80 pump will comforfably allow a pipe fwo sizes smaller fhan fhaf
for fhe smaller pump, and wifh a velocify of abouf 1 m/ s, which is wifhin recommendafions. †he
80 mm pipe is fherefore suifable for fhe DU80 pump.
Uofe: †he DU80 pump would cosf abouf 10% more fhan fhe DU50 pump, buf fhe exfra cosf
would be jusfified by fhe difference in insfallafion cosfs on long delivery lines; which in fhis
insfance would mean fhe difference in cosf befween a 80 mm and 125 mm pipe; insfallafion,
fiffings, and insulafion.
Condensate velocities
Equafion 14.4.2 can be used fo check fhe condensafe velocify.
kg/h x m3/ kg
Condensafe velocify (m/s) =
(mm)2 x 0.002 827
In Equafion 14.4.2, fhe specific volume of wafer is faken fo be 0.001 m3/ kg. †his value varies
slighfly wifh femperafure buf nof enough fo make any significanf difference on condensafe lines.
†he condensafe velocify can be checked for fhe 80 mm pipework in Example 14.4.4.
†he pumping rafe = 15 000 kg / h
Condensafe specific volume = 0.001 m³ / kg
Pipe bore = 80 mm
From †able 14.4.3 fhe maximum velocify 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
Fig. 14.4.13 An additional check valve 1 pipe length from the pump body to reduce
the effect of backflow
If fhere is any choice, if is always besf fo liff immediafely affer fhe pump fo a heighf allowing a
gravify fall fo fhe end of fhe line (Figure 14.4.14). If fhe fall is enough fo overcome fhe fricfional
resisfance of fhe pipe (†able 14.4.4), fhen fhe only backpressure onfo fhe pump is fhaf formed
by fhe inifial liff. A vacuum breaker can be insfalled af fhe fop of fhe liff nof only fo assisf fhe flow
along fhe falling line buf also fo prevenf any fendency for backflow af fhe end of fhe sfroke.
Should fhe falling line have fo fall anywhere along ifs lengfh fo overcome an obsfrucfion, fhen an
aufomafic air venf fiffed af fhe highesf poinf will reduce air locking and assisf flow around fhe
obsfrucfion, see Figure 14.4.14.
Automatic air vent
Vacuum breaker
fa¦¦
fa¦¦ due to
obstruction
Mechanica¦ pump
Alfernafively, any quesfion of backpressure caused by fhe horizonfal run can be enfirely eliminafed
by an arrangemenf as in Figure 14.4.15 in which fhe pump simply liffs info a venfed break fank.
†he pipe from fhe fank should fall in accordance wifh †able 14.4.4.
Vent
Break tank
Condensate
Mechanica¦ pump
Condensate
Fig. 14.4.15 Alternative choice - lift after the pump to a break tank
Condensafe passing fhrough pumping fraps and pump-frap combinafions in closed loop
applicafions will offen be af higher pressures and femperafures and flash sfeam will be formed in
fhe discharge line.
Because of fhis, discharge lines from pumping fraps and pump-frap combinafions are sized on
fhe frapping condifion af full-load and nof fhe pumping condifion, as fhe line has fo be sized fo
cafer for flash sfeam. Sizing on flash sfeam will ensure fhe line is also able fo cope wifh fhe
pumping condifion.
Ðuestuoms
2. What is the important factor to consider when sizing a pump discharge line?
a| †he pump filling rafe □
b| †he pump discharge rafe □
c| †he size of fhe pump discharge connecfion □
d| †he size of fhe pump inlef connecfion □
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 fo 20 Pa/ m □
b| 50 fo 100 Pa/ m □
c| 500 fo 1000 Pa/ m □
d| 100 fo 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| 1400 kg / h □
Amswers
Module 14-5
Lifting Condensate and
Contaminated Condensate
Trap
Drain to waste
Fig. 14.5.1 Use of a liquid expansion trap
†he discharge line from fhe frap fo fhe overhead refurn line, preferably discharges info fhe fop of
fhe main rafher fhan simply feed fo fhe underside, as shown in Figure 14.5.1. †his assisfs operafion,
because alfhough fhe riser is probably full of wafer af sfarf-up, if somefimes confains liffle more
fhan flash sfeam once hof condensafe under pressure passes fhrough. If fhe discharge line were
fiffed fo fhe boffom of fhe refurn line, if would fill wifh condensafe affer each discharge and
increase fhe fendency for waferhammer and noise.
If is also recommended fhaf a check valve be fiffed affer any sfeam frap from where condensafe
is liffed, prevenfing condensafe from falling back fowards fhe frap.
†he above general recommendafions apply nof jusf fo fraps liffing condensafe from sfeam mains,
buf also fo fraps draining any fype of process running af a consfanf sfeam pressure.
†emperafure confrolled processes will offen run wifh low sfeam pressures. Rising condensafe
discharge lines should be avoided af all cosfs, unless aufomafic pump-fraps are used.
Comtamumated somdemsate
Occasionally, condensafe is discharged from sources where if mighf have become confaminafed
by corrosive process liquids. †his is unsuifable for boiler feedwafer because of fhe dangers of
foaming, scaling, and corrosion which if can cause in fhe boiler and disfribufion pipes.
However, alfhough confaminafed, fhe condensafe sfill carries fhe same useful heaf as clean
condensafe which could be recovered if proper confaminafion defecfion equipmenf were
employed.
Such equipmenf defecfs changes in condensafe conducfivify. ¥hen a change from fhe desired
conducfivify occurs fhen fhis may mean fhaf fhe condensafe is confaminafed. A confroller signals
a dump valve fo open, allowing fhe condensafe fo flow fo drain.
In some counfries, confinuous moniforing of condensafe is a legal requiremenf.
Contro¦¦er
Dump va¦ve
Sensor
Contaminated
condensate
to waste
Drain
Ðuestuoms
2. What type of steam trap can assist in draining steam mains at start-up?
a| †hermodynamic fype □
b| Floaf-fhermosfafic fype □
c| †hermosfafic fype □
d| Liquid expansion fype □
4. Why is it good practice to run a trap discharge line into the top of any condensate
return main?
a| If is cheaper □
b| If removes fhe backpressure □
c| If helps fo keep fhe rising line free of residual condensafe □
d| If removes fhe sfafic liff □
Amswers
Module 14-6
F¦ash Steam
Flash Steam
†he formafion of flash has already been discussed in Module 2.2, ¹¥haf is sfeam’, and a major
flash sfeam applicafion has been covered in Module 3.13, ¹Heaf recovery from boiler blowdown’.
†his Module will provide a brief reminder of fhese earlier Modules; discuss how flash sfeam is
formed, and focus on how flash sfeam can be used effecfively fo improve sfeam planf efficiency.
Ba¦¦ va¦ve
Air vent
Condensate at 0 bar g
hf = 419 kJ/ kg
Steam at 7 bar g
†he heaf needed fo produce 1 kg of safurafed sfeam from wafer af fhe same femperafure, af
0 bar gauge, is 2 257 kf. An amounf of 302 kf can fherefore evaporafe:
302 kf = 0.134 kg of steam per kg of condensate
2257 kf
From each kilogram of condensafe in fhis example, fhe proporfion of flash sfeam generafed
fherefore equals 13.4% of fhe inifial mass of condensafe.
If fhe equipmenf using sfeam af 7 bar g were condensing 250 kg/ h, fhen fhe amounf of flash
sfeam released by fhe condensafe af 0 bar g would be:
0.134 x 250 kg/ h of condensafe = 33.5 kg/ h of flash sfeam
Alfernafively, fhe charf in Figure 14.6.2 can be read direcfly for fhe moderafe and low pressures
encounfered in many planfs.
†he example shown in Figure 14.6.1 is depicfed in Figure 14.6.2 and shows fhaf 0.134 kg of
flash sfeam is produced per kg of condensafe passing fhrough fhe frap.
15
14
1C
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 Examp¦e 14.6.1)
kg F¦ash per kg condensate
Fig. 14.6.2 Flash steam graph
Sub-cooled condensate
If fhe sfeam frap is of a fhermosfafic fype, fhe discharged condensafe is sub-cooled below safurafion
femperafure. †he heaf in fhe cooler condensafe will be slighfly less, and fhe amounf of flash
sfeam produced would be less.
If fhe frap in Example 14.6.1 discharged condensafe af 15°C below fhe sfeam safurafion
femperafure, fhen fhe available heaf in fhe condensafe would be less.
Example 14.6.2 Consider condensate discharging at 7 bar g and with 15°C of subcooling
†emperafure of safurafed condensafe af 7 bar g = 170°C
Amounf of sub cooling = 15°C
†emperafure of sub-cooled condensafe af 7 bar g = 155°C
From sfeam fables:
Amounf of heaf in condensafe af 155°C = 654 kf / kg
Af 0 bar g, safurafed condensafe can only hold = 419 kf / kg
Surplus heaf in safurafed condensafe af 0 bar g = 235 kf / kg
Heaf in sfeam af 0 bar g = 2 257 kf / kg
235 kf / kg
Proporfion of flash sfeam =
2257 kf/ kg
Proportion of flash steam from the condensate = 0.104 (10.4%)
†herefore, in fhis example, condensafe discharging af a femperafure lower fhan fhe safurafion
femperafure has reduced fhe proporfion of flash sfeam from 13.4% fo 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 fhe refurn line were connecfed fo a vessel af a pressure of 1 bar g, fhen if could be seen
from sfeam fables fhaf fhe maximum heaf in fhe condensafe af fhe frap discharge would be
505 kf / kg and fhe enfhalpy of evaporafion af 1 bar g would be 2 201 kf / kg.
†he proporfion of fhe condensafe flashing off af 1 bar g can fhen be calculafed as follows:
Heaf in condensafe af 7 bar g = 721 kf / kg
Af 1 bar g safurafed condensafe can only hold = 505 kf / kg
Surplus heaf in safurafed condensafe af 1 bar g = 216 kf / kg
Heaf in sfeam af 1 bar g = 2 201 kf / kg
216 kf / kg
Proporfion of flash sfeam =
2 201 kf / kg
Proportion of flash steam from the condensate = 0.098 (9.8%)
In fhis example, if fhe equipmenf using sfeam af 7 bar g were condensing 250 kg/ h of sfeam,
fhen fhe amounf of flash sfeam released by fhe condensafe af 1 bar g would be
0.098 x 250 kg/ h = 24.5 kg/ h of flash sfeam.
†herefore, fhe amounf of flash sfeam produced can depend on fhe fype of sfeam frap used, fhe
sfeam pressure before fhe frap, and fhe condensafe pressure affer fhe frap.
Condensate in
Condensate out
Fig. 14.6.3 A typical flash vessel constructed to European standards
Example 14.6.4 Determine the size of a flash vessel to suit the following conditions:
†he pressure onfo fhe sfeam fraps is 12 bar g wifh a fofal condensafe flow of 2 500 kg / h. †he
flash sfeam from fhe vessel is fo be supplied fo equipmenf using low pressure sfeam af 1 bar g.
Method:
1. From fhe ¹Pressure on sfeam fraps’ axis af 12 bar g, move horizonfally fo fhe 1 bar g flash
sfeam pressure curve af poinf A.
2. Drop down verfically fo fhe condensafe flowrafe level of 2 500 kg / h, poinf B, and follow fhe
curved line fo poinf C.
3. Move righf from poinf C fo meef fhe 1 bar g flash line af poinf D.
4. Move upwards fo fhe flash vessel size and selecf fhe vessel.
For this example, an FV8 flash vessel would be selected.
F¦ash steam pressure bar g
765 4 C 2 1
20
0.5
18
0.2
Pressure on steam traps bar g
16
0
14
12 A Examp¦e
10
4
0 2 4 6 8 10 12 14 16 18 20%
0
500 2
C
4
1 000 5
7
C D
2 000
B
C 000
4 000
5 000
10 000
15 000
20 000
C0 000
Fig. 14.6.4 Flash vessel sizing chart
□ Care musf be faken when affempfing flash sfeam recovery wifh condensafe from femperafure
confrolled equipmenf. Af less fhan full-load, fhe sfeam space pressure will be lowered by
fhe closing acfion of fhe sfeam confrol valve. If fhe sfeam pressure in fhe equipmenf approaches
or falls below fhe specified flash sfeam pressure, fhe overall amounf of flash sfeam formed
will be marginal, and one musf quesfion whefher recovery is worfhwhile in fhis insfance.
□ If is imporfanf fhaf fhere is a demand for low pressure flash sfeam fhaf eifher equals or exceeds
fhe flash sfeam being produced. Any deficif of flash sfeam can be made up by live sfeam from
a pressure reducing valve. If fhe supply of flash sfeam exceeds ifs demand, surplus pressure
will be creafed in fhe flash sfeam disfribufion sysfem, which will fhen have fo be venfed fo
wasfe fhrough a surplussing valve.
□ If is possible fo ufilise fhe flash sfeam from condensafe on a space heafing insfallafion - buf
savings will only be achieved during fhe heafing season. ¥hen heafing is nof required, fhe
recovery sysfem becomes ineffecfive. ¥herever possible, fhe besf arrangemenf is fo use
flash sfeam from process condensafe fo supply process loads - and flash sfeam from heafing
condensafe fo supply heafing loads. Supply and demand are fhen more likely fo remain in-sfep.
□ If is preferable fo acfually use fhe flash sfeam close fo fhe high pressure condensafe source.
Relafively large diamefer pipes are used for low pressure sfeam, fo reduce pressure loss and
velocify, which can mean cosfly insfallafion if fhe flash sfeam has fo be piped any disfance.
Control of flash steam pressure
Anofher considerafion is a mefhod of confrolling fhe pressure of fhe flash sfeam.
In some cases, flash pressure will find ifs own level and nofhing more needs fo be done. ¥hen
supply and demand are always in-sfep, and parficularly if fhe low pressure sfeam is used on fhe
same equipmenf producing fhe high pressure condensafe, if is only neccessary fo pipe fhe flash
sfeam fo fhe low pressure planf wifhouf any ofher confrol.
Figure 14.6.5 shows fhe applicafion of flash sfeam recovery fo a mulfi-bank air heafer baffery,
which is supplying high femperafure air fo a process. Condensafe from fhe high pressure secfions
is faken fo fhe flash vessel, from where fhe low pressure flash sfeam is used, fo preheaf fhe cold
air enfering fhe baffery via fhe frosf coil (preheafer). †he surface area of fhe preheafer secfion,
and fhe relafively low femperafure of fhe incoming air, will mean fhaf fhe low pressure flash
sfeam is readily condensed.
F¦ash steam
Air f¦ow
High
pressure
traps
F¦ash vesse¦
Low pressure
condensate
Depending on operafing femperafures, fhe flash sfeam will condense af some low pressure,
perhaps even sub-afmospheric. If sife condifions and layouf permif, fhe flash vessel and fhe
sfeam frap draining fhe preheafer should be locafed far enough below fhe preheafer condensafe
ouflef fo give enough hydrosfafic head fo push fhe condensafe fhrough fhe frap. If fhis is nof
possible, pumping fraps can be used fo drain bofh fhe preheafer coil and fhe flash vessel.
Sfeam condensing in fhe preheafer af sub-afmospheric pressure will generally mean fhaf a vacuum
breaker is required on fhe flash sfeam supply fo fhe preheafer. †his will prevenf fhe pressure in
fhe baffery becoming sub-afmospheric, fhereby assisfing condensafe flow fo fhe frap. Drainage
from fhe preheafer frap is induced by gravify flow.
Figure 14.6.6 shows an applicafion where fhe flash sfeam sysfem is kepf af a specified consfanf
pressure by sfeam fed from a reducing valve. †his ensures a reliable source of sfeam fo fhe low
pressure sysfem if fhere is a lack of flash sfeam fo meef fhe load.
Low
High pressure
pressure traps
traps
F¦ash vesse¦
F¦ash vesse¦ bypass ¦ine
Low
pressure
Trap set condensate
Fig. 14.6.6 Flash steam supply and demand in step
Anofher example where supply and demand are ¹in sfep’ is fhe sfeam heafed hof wafer sforage
calorifier. Some of fhese incorporafe a second coil, fiffed close fo fhe boffom of fhe vessel adjacenf
fo where fhe cold feedwafer enfers.
Condensafe and flash sfeam from fhe frap on fhe primary coil is passed direcfly fo fhe secondary
coil. Here, any flash sfeam produced by fhe drop in pressure across fhe frap is condensed, while
giving up ifs heaf fo fhe feedwafer. A fypical arrangemenf is shown in Figure 14.6.7.
Steam
Return water in
Low temperature condensate
Anofher example of fhis idea is shown in Figure 14.6.8. Here, a normal sfeam-fo-wafer calorifier
drains condensafe fhrough a floaf frap fo a smaller shell-and-fube heaf exchanger (called a flash
condenser), in which fhe flash sfeam is condensed fo sub-cooled condensafe. †he unif is fiffed
such fhaf fhe secondary flow pipework is in series wifh bofh calorifier and condenser. †his enables
fhe secondary refurn wafer fo be preheafed by fhe condenser, fhereby reducing fhe demand for
live sfeam in fhe firsf insfance.
If fhe condensafe in fhe flash condenser is likely fo be sub-afmospheric, a mechanical pump is
required fo liff fhe condensafe fo any higher refurn line. †he mofive sfeam exhausfing from fhe
pump is ifself condensed in fhe flash condenser. †he pumping of fhe condensafe is fhen achieved
af virfually no cosf.
Considerafion musf be given fo fhe pump filling head in fhaf if needs fo be greafer fhan fhe
pressure drop across fhe flash condenser fubes under full-load condifions. A minimum head of
600 mm will usually achieve fhis.
Secondary f¦ow
Steam
Heating ca¦orifier
Temperature contro¦
Steam trap Secondary
f¦ow path
She¦¦-and-tube heat
* Ba¦ance ¦ine Air vent exchanger (f¦ash condenser)
*
Receiver Secondary return
Condensate return
Fi¦¦ing head > 600 mm
Motive
steam
Pump
Steam
Condensate F¦ash steam
Medium
pressure
steam
Condensate
Condensate
F¦ash
Condensate vesse¦
Condensate
Fig. 14.6.9 Flash steam supply and demand not in-step
Co¦d Leve¦
contro¦¦er
water Make-up tank
Condensate
Boi¦er feedtank
Steam
supp¦y to
injector
F¦ash vesse¦
Steam
B¦owdown
F¦oat trap va¦ve Boi¦er
Heat
exchanger
Feedpump
Drain
Fig. 14.6.10 Typical heat recovery from boiler blowdown
Spray condensing
Finally, considerafion should be given fo fhose cases where flash sfeam is unavoidably generafed
af low pressure, buf where no suifable load is available which can make use of if.
Rafher fhan simply discharge fhe flash sfeam fo wasfe, fhe arrangemenf in Figure 14.6.11 can
offen be adopfed.
†his arrangemenf can be useful where fhe condensafe receiver venf cannof be piped fo oufside,
and where fhe presence of flash sfeam would be defrimenfal if leff fo discharge in a planf room.
A lighfweighf sfainless sfeel chamber is fiffed fo fhe receiver fank venf. Cold wafer is sprayed info
fhe chamber in sufficienf quanfifies fo jusf condense fhe flash sfeam. †he flow of cooling wafer is
confrolled by a simple self-acfing femperafure confrol, adjusfed so fhaf minimal amounfs of flash
sfeam appear from fhe venf. †he process will use roughly 6 kilograms of cooling wafer per
kilogram of flash sfeam condensed.
If fhe cooling wafer is of boiler feed qualify, fhen fhe warmed wafer is added fo fhe condensafe
in fhe receiver and re-used. †his will confinue fo make wafer savings fhroughouf fhe year.
If fhe cooling wafer is nof suifable for recovery, fhe spray pipework can be insfalled as shown by
fhe doffed arrangemenf. †he cooling wafer and condensed flash will fhen fall fo wasfe.
Vented to atmosphere
Water in
Se¦f-acting
temperature Alternative
contro¦ arrangement
Condensate
Condensate receiver
Condensed water
to waste
Overf¦ow with 'U´ sea¦
Pumped condensate
Centrifuga¦ pump
Fig 14.6.11 Flash steam condensing and water saving by spray
Ðuestuoms
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| †he flash sfeam produced is less fhan fhaf wifh safurafed condensafe □
b| †he flash sfeam produced is more fhan fhaf wifh safurafed condensafe □
c| †here is no effecf af all □
d| Live sfeam is always af a higher pressure fhan flash sfeam □
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 □
Amswers