Chapter 1

Installation
Condensate Transfer pump
Committed to deliver innovative energy solutions
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1.1 Description
Condensate Transfer Pump

TACTS is a plug in system specifically designed to collect and pump hot condensate, commonly
returned for use as boiler feed water. The whole system is capable of handling capacities up to
16000 kg/hr. The pump can be operated by steam or compressed air/gas and can be tailored to
meet a wide variety of condensate handling applications. Larger condensate handling capacities
available in simplex, duplex & triplex pumps.
The pump works on the principle of positive displacement using motive steam or compressed air
pressure. Condensate flows by gravity from receiver to the pump chamber through
interconnecting piping and inlet non-return valve. The Conductivity based level switch in the pump
chamber senses whether the condensate level in the chamber has reached to the upper set level.
When condensate level reaches the upper set point, a 3-way valve is energized allowing motive
steam in the pump body. This motive steam is normally set at pressure above the condensate
discharge head required. Pressure in the pump keeps on building till it is just sufficient to overcome
the back pressure. The pressurized liquid opens the outlet check valve and discharge of condensate
commences. The inlet disc valves fitted in the pump prevent any back flow to the receiver. During
this period incoming condensate is stored in the receiver.
Condensate is discharged out of pump chamber till the level reaches to the lower level. When level
reaches minimum lower level it de-energizes the 3-way valve and opens the vent port. The pump is
depressurized and condensate starts flowing in the pump from receiver again.
The filling and discharge cycles are repeated. The frequency of cycles depends upon condensate
flow in to the receiver from the plant. A digital indication of total condensate pumped is provided.
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1.2 Technical Specifications

Selection Table for TACTS
200i 300i 400i 500i 600i
Operating Total
Inlet Lift /
Motive back TACTS TACTS TACTS TACTS TACTS TACTS TACTS TACTS TACTS TACTS
Pressure pressure plus ultra plus ultra plus ultra plus ultra plus ultra
kg/cm2g kg/cm2g LPH LPH LPH LPH LPH LPH LPH LPH LPH LPH
2 0.5 1100 1190 2380 2860 3315 3790 5150 5400 9180 12285
1 1035 1150 2075 2550 2910 3460 4355 4520 8370 11070
3 0.5 1180 1260 2500 3000 3505 4080 5655 5980 10260 13770
1 1140 1200 2335 2770 3335 3830 4850 5100 9315 12555
1.5 1110 1170 2170 2560 3130 3600 4670 4840 8775 11745
2 1030 1050 1920 2320 2905 3410 4250 4350 7695 10260
4 0.5 1240 1300 2625 3100 3995 4290 5915 6390 11070 14850
1 1170 1240 2480 2920 3800 4090 5275 5510 10125 13500
1.5 1135 1200 2240 2670 3455 3790 4905 5200 9180 12285
2 1060 1090 2040 2460 3145 3520 4160 4570 8370 11205
3 890 940 1765 2090 2670 2880 2530 2810 7560 10125
5 1 1215 1270 2560 3030 4040 4290 5570 5830 10665 14175
1.5 1165 1230 2285 2760 3815 3950 5190 5480 8910 12015
2 1095 1130 2170 2560 3385 3600 4342 4743 8100 10935
3 955 980 1940 2230 2945 3040 3140 3260 8100 10800
6 1 1240 1300 2665 3130 4235 4460 5745 6090 11070 14850
1.5 1190 1250 2430 2830 3900 4070 5415 5700 10530 14040
2 1100 1150 2260 2650 3479 3670 4600 4880 9450 12555
3 970 1020 1995 2340 3009 3170 3430 3620 8640 11475
4 960 990 1710 1980 2520 2630 3300 3530 8505 11340
7 1 1320 3210 4210 6310 15255
1.5 1270 2890 4170 5900 14445
2 1180 2720 3720 5000 13095
3 1050 2440 3280 3930 12015
4 1020 2030 2680 3630 11880
8 1 1340 3280 4320 6400 15795
1.5 1280 2940 4260 6070 14985
2 1200 2780 3770 5100 13500
3 1070 2520 3380 4200 12420
4 1040 2080 2720 3710 12285
9 1 1350 3340 4420 6510 16200
1.5 1290 2980 4340 6210 15390
2 1220 2840 3820 5190 13905
3 1100 2600 3460 4440 12825
4 1060 2120 2760 3780 12690
10 1 1370 3400 4510 6620 16470
1.5 1310 3020 4410 6340 15795
2 1230 2890 3850 5270 14310
3 1120 2660 3540 4647 13230
4 1080 2150 2800 3850 13095
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Dimensional Drawings

* Please refer Standard GA Drawing

Design Specifications
Design Code ASME Sec VIII Div 1
Design Pressure Receiver kg/cm2 (g) 3.5
Design Pressure Pump kg/cm2 (g) 11

Design Temperature o
C 187
Normal Operating Conditions
Steam / Air Pressure kg/cm2 (g) 10 Max
Steam Temperature o C 164
Pump Discharge Pressure kg/cm2 (g) 5 Max

Models and End Connections

Condensate Condensate Motive Receiver Pump Drain Over flow Trap line Pump Vent
Model Inlet to receiver Outlet from pump Steam Inlet Vent
(N1, N1A) (N2) (N3) (N4) (N7) (N6)
TACTS PLUS 200i/ 50 NB X 2 25 NB 15 NB 50 NB 25 NB, Scr BSP 40 NB 15 NB 15 NB
TACTS ULTRA 200i
TACTS PLUS 300i/ 50 NB X 2 40 NB 15 NB 50 NB 25 NB, Scr BSP 40 NB 15 NB 15 NB
TACTS ULTRA 300i
TACTS PLUS 400i/ 50 NB X 2 50 NB 15 NB 80 NB 25 NB, Scr BSP 40 NB 15 NB 15 NB
TACTS ULTRA 400i
TACTS PLUS 500i/ 50 NB X 2 80 NB 15 NB 80 NB 25 NB, Scr BSP 40 NB 15 NB 15 NB
TACTS ULTRA 500i
TACTS PLUS 600i/ 80 NB X 2 100 NB 15 NB 100 NB 25 NB, Scr BSP 40 NB 15 NB 25 NB
TACTS ULTRA 600i
End Connections : Flanged To ANSI B 16.5 Class # 150
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1.3 Safety Instructions

Safe operation of the unit can only be guaranteed only if qualified person performs
the installation and commissioning of the equipment’s in compliance with the
instructions given in the manual.

General installation and safety instructions for pipeline and plant construction, as
well as the proper use of tools and safety equipment must also be complied with.

1.4 Transportation, Unloading and Storage

1. Unloading
Unit should be lifted for loading/unloading or shifting from one position to another
by supporting from the base frame/hooks provided for lifting purpose.
Do not use receiver for lifting the pump by using sling on it.
Packing slip supplied with the material and the no of cases to be verified at site.
receipt of goods, please verify whether cases are intact otherwise to be reported for
Insurance claim

The wooden pack cases should be opened only in presence of Thermax engineer or
Thermax authorized representative/dealer.

2. Storage
Goods should be protected from rainwater and direct sunlight.
Do not store goods in corrosive environment.
Do not pile up cases.
Do not store on soft soil.
Life of wooden case is only 3 months

3 Foundation
Pump should be installed on levelled RCC foundation.
The foundation pad should be at least 100 mm above finished floor level
Refer applicable GA drawing for foundation details.
Leave free space of 1m all around for ease of maintenance, cleaning and movement.
4. Grouting and Levelling
Anchor bolt of M14 size should be grouted while casting the foundation.
The projection of anchor bolt should be 35 mm above the foundation surface.
The anchor bolt should be of L or T type.
Ensure proper draining system to drain water, which will get accumulated within
the base frame.

5. Location of TACTS
TACTS should be installed adjacent to the user plant.
Ensure proper flow of condensate by gravity.

If a flash vessel (TAFS) is installed for recovery of flash steam ensure minimum
head of 500 mm between the centre line of flash vessel outlet nozzle and
TACTS receiver nozzle top.

This is mandatory requirement for proper operation of TACTS

If the above is not possible we suggest installation of TACTS in a suitably

sized pit provided with a sump and sump drain pump.

If pit drainage arrangement is not provided the pit may get

flooded with water causing damage to TACTS
components.

Do the necessary arrangement to drain the pump and receiver to the sump
pit at a visible level.
Ensure that the vent of receiver is piped to a safe place preferably with no bends.

Size of the vent pipe is not to be reduced

The pit to be provided with a dyke wall to prevent water from re-enter
inside the pit.
The pit to be covered with suitable asbestos, plastic / GI sheet roof.

When air is used as motive, close the steam trap outlet in motive
Steam / air line.
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1.5 Erection Guidelines

Check foundation for readiness and dimensions.

The pump discharge is intermittent and the pump discharge header has to be
designed to handle three times the capacity of the pump.

Check availability of all utilities like steam, compressed air and single-phase
electrical supply at 230 V AC, 50 Hz.
In case of pit installation of TACTS the over flow line and Air vent line is to be taken
out from pit to safe drain point outside the pit to avoid accumulation of water inside
the pit. The drain line of solenoid valve should connect to Air vent line.

Dike walls must be built to surround the pit to avoid water on FFL
to enter inside the pit.

If pit should be built with water collection chamber of minimum

capacity of 100 Litre accumulation capacity.

In pit installation provides a single phase pump to lift the accumulated condensate in
the pit sump.
Provide Separate Earth connection to TACT.
Provide line Earth connection to controller also.

Voltage between Neutral and Earth should not be more than 3 Volts.

Single phase 1 KVA CVT / UPS is recommended for controller.

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PIT Installation
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1.6 Erection Procedure

1. Install the TACTS the prepared foundation. Level it, fill the pocket with grouting material.
2. Once the grouting is cured, check the level and tighten the foundation nuts.
3. Connect the pump discharge line to header taking condensate to feed water tank /
TADIT.
4. Connect plant condensate line to the nozzles (N1) provided on the receiver.
5. Route the vent line to a safe location from nozzle (N4) with minimum bends.
6. Route the pump drain (N7)-to-drain pit / drainage system.
7. Receiver overflow (N6) drain line to be taken down to the non-pressurized drainage
system with minimum bends and with proper sloping.
8. Keep a 1” BSP hose nipple and hosepipe ready for connecting receiver drain (N5) to
drainage system temporarily for initial flushing of the receiver.
9. The site-fabricated item is to be flushed by using low-pressure steam or compressed air
before connecting to TACTS Check this with the customer/ piping contractor and get
the confirmation.
10. Connect motive steam to the nozzle (N3) as shown in the GA drawing.
11. Connect compressed air to air filter regulator (AFR) with isolation needle
valve(customer scope) for operating the 3 way valve.
12 Lay power cable of size 3 core 1.5 mm 2 armored with earth connection cable
connected to the ground from main isolation switch to TACTS controller.
13 Directly connect the 230 V AC power supply to the respective cable of the TACTS
+ controller as per wiring drawing
14. The power cable to be connected to the controller with a double compression cable
gland. Care must be taken to ensure proper sealing to avoid moisture entry into the
controller.
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Chapter 2

Pre Commissioning,
Commissioning and Operation
Condensate Transfer pump
Committed to deliver innovative energy solutions
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2.1 Pre Commissioning Check Points

1. Start the pre commissioning activities after ensuring that the piping system is as per
P&I diagram and the same has been hydro/pneumatically tested by the customer.
2. Check whether flushing is done properly.
3. Open drain plug of the pump receiver (N5) and connect a hosepipe with hose nipple.
4. Close the butterfly/ball valve between the receiver and the pump chamber.
5. Fill water in the receiver through the nozzle N1 or N4 whichever is not connected
and flush the receiver tank completely.
6. Close the receiver drain plug (N5).
7. Fill the receiver with water again.
8. Remove the strainer cover of 'Y' strainer between receiver and pump chamber.
Open the butterfly/ball valve and let the water come out. Continue till clean water
comes out.
9. Refit the cover after cleaning the strainer screen with jet of water.
10. Keeping the butterfly/ball valve open allow the water to flow into the pump chamber,
keeping the pump outlet valve closed (Valve in customers scope). When the pump
has been filled, open the pump drain valve.
11. Continue flushing the pump body with water till clean water starts coming out. Close
the pump drain valve at the end of flushing operation.
12. Open the motive steam inlet valve slightly, keep the thermodynamic trap inlet valve
closed, open the thermodynamic trap bypass valve. Flush the line with steam. Keep
an aluminium sheet in front of the nozzle to detect the presence of solid particles in
line. Presence of solids will make sound and dents on the sheet. Stop the steam
flushing after the sound of particles hitting the aluminium sheet stops. Close both
steam inlet and thermodynamic trap by pass valves.
13. Open the 'Y' strainer in the steam line after the steam line has cooled. Clean the
strainer screen under a jet of water and refit.
14. Electrical connections TACTS
a) Tighten all electrical connections of the controller.
b) Check the supply with multi meter before switching it ON. It should be 230 +/- 3
%. Between earth and neutral, it should be less than 3 Volts.
c) Switch on the power supply and check that the indicator light is ON.
15 a) Switch on the power supply and check the LED indication
b) Red LED glowing indicates high level.
2
16. Start the instrument air supply and adjust the air pressure to 4 to 6 kg/cm .
17. Drain any water accumulated in the air filter regulator (AFR).
18. Open valves in the condensate line and check its flow by opening the drain valve in
the condensate line before it enters TACTS.
19. Ensure steam supply pressure between 2 to 6 kg/cm2. Adjust PRV if required
(customer's scope).
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Now the system is ready for commissioning

Isolate TACTS completely during hydro/ pneumatic testing of site fabricated items.
Proper safety precautions to be taken while flushing the pump with steam.

For checking the solenoid coil, do not connect 230V supply directly to
solenoid coil until it is mounted on valve otherwise it may get burnt.

2.2 Commissioning
1. Switch on the power supply.
2. Open instrument air inlet valve and ensure air pressure on AFR.
3. Open motive steam inlet valve to TACTS.
4. Open Thermodynamic trap bypass valve for some time initially to remove
condensate due to higher start up load. Once steam starts coming out of this valve
close the bypass valve and open the thermodynamic inlet valve gradually.
5. Open butterfly/ball valve between receiver and pump chamber.
6. Open slightly valves in condensate line to TACTS.
7 Water enters the receiver and flows to the pump chamber. Green LED glows until the
level reaches the high Level mark. This is represented by glowing of orange LED. Steam
enters the pump, which can be detected by click sound of solenoid valve. Condensate is
pumped out through outlet piping, and level starts falling, known as discharge stroke. On
reaching the low level, green LED starts glowing and motive steam supply stops. The vent
port of 3 way valve opens and motive steam is exhausted to atmosphere. Once the
Pressure reaches atmospheric, the water Restarts filling the pump, referred to as filling
stroke.
The sequence of filling and discharge continues
8. Observe the filling and discharge strokes for few cycles.
9. Open the condensate inlet valve fully to allow full condensate load to pump.
10. The system is now commissioned.
11. Alternatively, the system can be commissioned by using cold water if steam condensate is
not available by following steps as indicated above. The only difference being a temporary
connection for cold water supply to be given directly to the receiver of
TACTS.
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2.3 Controls and Safeties

An automatic overflow ensures safety against over pressure of the receiver.
Electrical supply to solenoid valve is protected by an MCB, which will trip the
circuit in case of any abnormal supply/short circuit at the output of MCB.
For main supply, main fuse protection is provided.
The pump will stop in fail-safe condition (pump chamber depressurized) in case
of failure of utilities like electricity, compressed air.

2.4 Operation
Starting the pump
1. Switch on the power supply
2. Open the instrument air inlet valve
3. Open the motive steam inlet valve
4. Open butterfly/ball valve between receiver and pump body
5. Open condensate inlet valve
6. Close the condensate bypass valve
7. Observe whether proper discharge strokes are taking place
8. Now the pump is operational

Stopping the pump

1. Close the condensate inlet valve
2. Open the condensate bypass valve
3. Close the motive steam inlet valve
4. Switch off the power supply
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2.5 Trouble Shooting

Cause / Check
Symptom Remedy
Points
Strainer between
Receiver and pump body Clean Strainer Screen
choked
Receiver
Overflows Inlet DCV struck closed Open, Clean, Lap if
or fails required & Refit or
change DCV
Level controller malfunction Check wiring
Check power supply
Check fuse of Totaliser

Outlet DCV fails Open, clean, lap if required or

replace DCV

Coil of air solenoid Replace coil

Condensate valve fails
overflow from 3 way valve fails Check fuse in controller.
vent port of
Loose connection in terminals.
3 way valve Replace 3 way valve

Depressurize the pump body by

Outlet DCV fails in closed
condition (Leaking)
Discharge stroke
continues for a
long time
3 way valve fails with
steam port open
opening the drain valve, closing
the butterfly / ball valve & steam
inlet valve. Remove, clean, refit or
replace DCV
Replace 3 way valve

Live steam 3 way valve leaking Replace the 3 way valve

coming from
vent port of 3 Insufficient air pressure Check air pressure
way valve to valve after regulator
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Improper insulation of Do proper insulation of

condensate inlet & outlet the pipe line
line

Insulation not provided Provide insulation

to condensate inlet &
outlet line
Flash Vessel & Condensate Install pump at recommended
pump height difference is height
Hammering at
not as per recommendation
condensate line
Slope in Condensate inlet Provide proper slope
/outlet line is not provided to the lines

Too many bends in the Inlet Keep nos of bend less

& outlet Line as possible
Use long bends only
Flash vessel trap not Check the trap module for
working blockage
Check Trap valve

TACTS conductivity based level controller malfunction

Mains Voltage not applied Apply mains voltage. Carry out

the device wiring in accordance
with the wiring diagram
Level exceeded
– High level switch
point not operating
Thermal fuse failed ·Replace the fuse in the case of
defective thermal fuse.
Ambient temperature must
not be over 70° C.
 Electric conductivity is Check and set the
very low DIP switch (L) in a conductivity
level of > 0.5 µS/cm

No earthing Wipe off the seating surface and

place metal insulating seal

Electronic card defective Replace the electronic card.

Level exceeded –
Electrode rods have Change the assembly /
Low level switch
point not ground contact installation position.
operating

Contact point Contact function not Cut electrode rods to

assessed: arranged correctly. Electrode correct sizes.
misoperation rods cut to incorrect sizes.

Flow Totaliser Electronic card faulty Send it for repair

Ocon+
malfunction

High fluctuations in Check fuse and replace

power supply if necessary
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Chapter 3

Maintenance,
Log Book and Spares
Committed to deliver innovative energy solutions
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3.1 Preventive Maintenance

Gland tightening of gate and gate valve /replacement as and when leakage detected.
Strainer/filter /AFR cleaning once in a week.
Tightening of electrical contacts of terminal strip on Level Controller once in a month.
Level controller float checking on quarterly basis.
Draining of pump vessel once in a month to remove dirt, scale etc.

3.2 Training and Log Book

Thermax engineers while installation and commissioning impart Training on
operation and maintenance of the product installed. For additional training needs
please contact nearest Thermax regional office.

Log Book Record data of various parameters at regular intervals is necessary to

be maintained. The data would include no of strokes, condensate quantity pumped,
steam pressure and back pressure. Logbook should also have records of
maintenance, failure and replacement of components.

3.3 Spare Parts

It is suggested that certain spare may be kept in stock to avoid idle time due to
unpredictable breakdowns.
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Chapter 4

List of Recommended Spares

Committed to deliver innovative energy solutions

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Part Description Spare Description Quantities

TACTS 200
TACTS 300
TACTS 400
TACTS 500
TACTS 600
1 3 Way Pneumatic 3 way valve & Actuator, 1 1 1 1 1
Valve with actuator 15 NB

2 Solenoid Valve Solenoid Valve 1 1 1 1 1

3 Solenoid Valve Solenoid Coil 1 1 1 1 1

4 OMRON Controller Conductivity Based Level 1 1 1 1 1

Controller

5 Flow Indicator Ocon+ Flow Indicator 1 1 1 1 1

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Chapter 5

Annexure

Committed to deliver innovative energy solutions

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5.1 TACTS Conductivity Based Level Controller

7 1

2
1 1. Cover Cap
3
2. Flange
6
3. Probe: High level

4 4. Probe: Low level

6 5. Probe: Reference

6. Electrode Separators
5
7. Cable Gland
Thermax Level Sensor

Omron Controller /Relay

Model 61F-GP-NH
INTRODUCTION & WORKING PRINCIPAL:
TACTS level controller works on the basis of conductivity principle. It senses the
high and low levels when a conductive fluid comes in contact with the respective
probes.
These controllers are very reliable and respond to conductivities as low as 0.5µS/cm.
This input is used to control the inlet and outlet of the process by activating relay’s
in the controller as per configuration.
FEATURES
CE approved reliable controller
LED indication for high level
PTFE lined electrodes
230 V AC supply, easy installation

STANDARD SETTINGS
1 Factory setting
Compact system is delivered together with the following factory
setting : Conductivity level 0.5 µS/cm
Contact delay 0 sec
230 V supply voltage
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5.2TACTS Flow Totalizer O-con+

INTRODUCTION AND WORKING PRINCIPLE

TACTS flow totaliser is used with conductivity based level controller.

TACTS works on the signal of low level and high level detected by conductivity based
level controller. This input is used to control the inlet and outlet of the process by
activating relays in totaliser as per the configuration. It also counts the cycles and
converts it into volume.

FEATURES
DISPLAY

1 LINE X 8 CHARACTER LED DISPLAY

VIEW PARAMETERS
Volume calculations using a multiplication factor and display in ltrs

CIRCUITARY
Microcontroller based inputs
Low and high level contacts from sensor
RELAYS
Relay Output 1 no. Contact rating 230 V AC, 5 A
It has to be used for solenoid valve operation

PROGRAMMING
4 digit security code.

SUPPLY
Universal input from 70 V AC to 270 V AC, 50 Hz
Ambient temperature: 70 deg C

ENCLOSURE
Wall mounting, ABS plastic, weather proof IP 65
Size: 220 (L) x 120 (H) x 90 (D) mm

RESET FLOW TOTALISER

5.3 Three Way Solenoid valve

To pump vessel

2 4

3
Exhaust

1. Actuating solenoid valve

2. Motive Steam/Air to Pump vessel

3. Motive Steam/Air Inlet

4. Motive Steam/Air Exhaust

5.4 Wiring for TACTS