TECHNICAL REFERENCE GUIDE

Condensate and flash steam recovery

Contents
Introduction Condensate return Why return condensate and reuse it? Condensate recovery cost saving example Condensate return lines Drain lines to traps Discharge lines from traps Discharging into flooded return lines Common return lines Temperature controlled plant with steam traps draining into flooded lines Discharge lines at different pressures Discharge lines from vented pumps Sizing condensate lines Sizing drain lines to traps From steam mains From process applications Sizing discharge lines from traps Recommendations on trap discharge lines The condensate pipe sizing chart Sizing common return lines Sizing pumped return lines Pumping traps and pump-trap installations Condensate pumping from vented receivers Pumping terminology Electrical centrifugal condensate pumps Sizing an electrical condensate recovery unit Sizing the discharge pipework for an electrical condensate recovery unit Mechanical condensate pumps Sizing a mechanical condensate pump Sizing the discharge pipework for a mechanical condensate pump Longer delivery lines Fully loaded pumps and longer lines Consideration of a larger pump and smaller pipeline Lifting condensate from steam mains drain traps Contaminated condensate Stall and the stall point The stall cycle Temperature controlled plant Condensate drainage to atmosphere Closed loop condensate drainage Determining the stall point on controlled plant Using the stall chart A typical stall chart Constant pressure plant 3 4 4 6 9 9 10 10 11 13 13 14 14 15 15 16 18 20 21 29 31 33 34 34 37 38 39 41 43 45 45 46 47 50 51 52 52 54 54 55 57 57 60 61 1

Contents

Flash steam What is flash steam and why should it be used ? How much flash steam ? Sub cooled condensate Pressurised recovery The flash vessel Sizing flash steam recovery vessels Requirements for successful flash steam applications Control of flash steam pressure Typical applications for flash steam Flash steam supply and demand in-step Flash steam supply and demand not in-step Boiler blowdown heat recovery applications Spray condensing Steam tables Further information Appendix 1 - Condensate line sizing chart

62 63 64 64 65 66 66 68 68 70 70 73 74 76 78 80 81

Introduction
Steam is usually generated for one of two reasons : to produce power, as in power stations and co-generation plants. to carry energy for heating and process systems. When a kg of steam condenses, a kg of condensate at the same pressure and temperature is formed. An efficient steam distribution system will make good use of this condensate. Failure to do so makes no financial, technical or environmental sense. Steam, used for heating, gives up its latent heat, which is a large proportion of its total heat. The remainder is held by the condensed water. As well as having heat content, the condensate is also a distilled form of water, which is ideal for use as boiler feedwater. An efficient installation will collect condensate and either return it to the deaerator, boiler feedtank, or use it in another process. Only when there is a real risk of contamination should condensate not be returned to the boiler. But then it may be possible to collect the condensate and use it as hot process water or pass it through a heat exchanger where its heat content can be recovered before discharging to drain. Condensate is discharged through traps from a higher to a lower pressure. As a result of this drop in pressure, some of the condensate will then re-evaporate into 'flash steam'. The proportion that will 'flash off' is determined by the pressure difference between the steam and condensate sides of the system, and a figure of 10 % to 15 % by mass is typical. However, the percentage volumetric change can be considerably more. Condensate at 7 bar g will lose about 13 % of its mass when flashing to atmospheric pressure, but the steam produced will require a space some 200 times larger than the condensate from which it was formed. This can have the effect of choking undersized trap discharge lines, and should be taken into account when sizing these lines. The flash steam generated can contain up to half of the total energy of the condensate, hence flash steam recovery is an essential part of an energy efficient system. Condensate and flash steam discharged to waste means replacement feedwater, more fuel, and increased running costs. This technical reference guide will look at two essential areas condensate management and flash steam recovery. Some of the apparent problem areas will be outlined and solutions offered. Illustrations, together with tables and charts to which reference is made, are included in the text. Basic steam tables can be found at the end of this guide. Note: the term 'trap' is used to denote a steam trapping device which could be a steam trap, a pumping trap, or a pump-trap combination. The ability of any steam trap to pass condensate relies upon the pressure difference across it, whereas a pumping trap or a pump-trap combination is able to remove condensate irrespective of pressure differences across it. 3

Condensate return
An effective condensate recovery system, collecting the hot condensate from the steam using equipment and returning it to the boiler feed system, can pay for itself in a remarkably short period of time. Fig. 1 shows a typical steam and condensate circuit, where condensate is returned to the boiler feedtank.
Steam Pan Pan Process vessel Space heating system

Steam Vat Vat Condensate

Make-up water Condensate Steam Feedtank

Boiler

Feedpump

Fig. 1 A typical steam and condensate circuit Why return condensate and reuse it? Monetary value. Condensate is a valuable resource and even the recovery of small quantities is often economically justifiable. The discharge from a single steam trap is often worth recovering. Unrecovered condensate is replaced by cold make-up water with additional costs of water treatment and fuel to heat the water from a lower temperature. Water charges. Any condensate which is not returned needs to be replaced by make-up water, incurring further water charges from the local water supplier. Effluent restrictions. In the UK for example, water above 43C cannot be returned to the public sewer because it is detrimental to the environment and may damage earthenware pipes. Condensate above this temperature must be cooled if discharged, which could incur extra energy costs. Similar restrictions apply in most countries and effluent charges and fines may be imposed by water suppliers for non-compliance. 4

Saturated steam temperature C

kJ/kg

100 2 800 2 600 2 400 2 200 2 000 1 800 1 600 1 400 1 200 1 000 800 600 400 200 0 0

120

134

144

152

159

165

170

175

180

184

188

192

195

198

Total heat of steam

Latent heat (entha

lpy of evaporatio

n)

ensate at eat in cond

erature steam temp Heat available for flash steam release to atmospheric pressure

Heat in condensate at atmospheric pressure

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Pressure bar g

Fig. 2 Heat content of steam and condensate Figure 2 shows the relative amounts of energy in steam and condensate at various pressures. Maximising boiler output. Colder boiler feedwater will reduce the steaming rate of the boiler. The lower the feedwater temperature, the more heat,and thus fuel needed to raise steam. Boiler feedwater quality. Condensate is a distilled water which contains almost no dissolved solids (TDS). Blowdown is used to reduce the concentration of dissolved solids in the boiler. More condensate returned to the feedtank reduces the need for blowdown and thus reduces the energy lost from the boiler. Summary of reasons for condensate recovery. Water charges are reduced. Effluent charges and possible cooling costs are reduced. Fuel costs are reduced. Boiler blowdown is reduced - less energy lost from boiler. Chemical treatment is reduced.

Condensate recovery cost saving example

The following example demonstrates how savings are possible by returning condensate to the boiler feedtank. Savings will obviously depend on the cost of fuel and water, and this example gives typical costs in the UK at the time of writing. The fuel used in this example is a heavy fuel oil with a gross calorific value of 42 MJ/litre. Fuel savings based on the following average temperatures Condensate return temperature = 90C Make-up water temperature = 10C Temperature difference = 80C Each kg of condensate not returned must be replaced by 1 kg of cold make-up water that will need heating to the same temperature. Heat required to raise 1 kg of cold make-up water by 80C: 1 kg x 80C x 4.19 kJ/kg C = 335 kJ/kg Basing the calculations on an average of 10 000 kg/h evaporation rate, and where none of the condensate is presently returned, 24 hours a day, 7 days a week, 50 weeks of the year (8 400 h/year), the nett energy required to replace the heat in the make-up water is: 10 000 kg/h x 335 kJ/kg x 8 400 h/year = 28 140 GJ / per year If the average boiler efficiency is 85 %, gross energy needed to heat the make-up water 2 8140 GJ / year = 33106 GJ/year 0.85 With a calorific value of 42 MJ / litre, potential savings on fuel 33106 GJ / year = 788 000 litres / year 42 MJ / litre With fuel at 0.15 / litre, cost savings Therefore, potential annual fuel savings = 788 000 x 0.15 = 118 200

Water savings. Total amount of water required in one year to replace condensate which is not returned: 8 400 h x 10 000 kg/h = 84 000 m 1 000 kg/m Costed at 0.61 per m: = 51 240 Therefore potential annual water savings = 51 240 6

Effluent savings. The condensate that was not recovered would have to be discharged to waste which may also be charged by the water authority. Total amount of water to waste in one year also equals 84 000 m If effluent costs 0.45 per m Therefore, potential annual effluent savings = 37 800 = 37 800

Total potential savings. The total annual potential savings for 10 000 kg/h evaporated based on none of the condensate presently being returned are : fuel savings water savings effluent savings total savings = = = = 118 200 51 240 37 800 207 240

It follows that for each 1% of condensate returned per 10 000 kg/h evaporated in the above example, a saving of 1% of each of the above values would be possible. To calculate relative savings based on the same reasoning, use the formulae on the next page by putting figures in the blank boxes. Fuel savings Water savings Effluent savings Total
(on 80C increase in feedwater)

= = = =

This sample calculation does not include a value for savings due to correct TDS control and reduced blowdown which will further reduce water loss and boiler chemical costs. These can vary substantially from location to location, but should always be considered in the final analysis. Consult Spirax Sarco for advice regarding any specific installation. Further information on how to calculate savings by automatic TDS control is available in the Spirax Sarco Technical Reference Guide TR-GCM-01, 'Water treatment, storage and blowdown for steam boilers'. Clearly, when assessing condensate management for a specific project, such savings should be determined and included. 7

Fuel savings

Savings in currency used in 'D' = 335 x A x B x C x D E x F where: A = average evaporation rate in tonnes/h B = hours per year C = percentage increase in condensate return D = cost per unit of fuel ( / litre; / therm; / kg) E = calorific value of fuel per same unit ( MJ / litre; MJ / therm; MJ / kg) F = boiler efficiency eg, consider the previous example, if a 30 % increase in condensate return is to be made, annual cost savings on fuel: 335 x 10 x 8 400 x 30 x 0.15 42 x 85 fuel savings = 35 470

Water savings

Savings in currency used in 'C' = A x B x C 100 x D

where: A = average evaporation rate in tonnes/h B = hours per year C = cost per m of water D = percentage increase in condensate return eg, consider the previous example, if a 30 % increase in condensate return is to be made, annual cost savings on water: 10 x water savings = 15 372 Effluent savings Savings in currency used in 'C' = A x B x C x D 100 where: A = average evaporation rate in tonnes / h B = hours per year C = cost per m of effluent D = percentage increase in condensate return eg, consider the previous example, if a 30 % increase in condensate return is to be made, annual cost savings on effluent : 10 x 8 400 x 0.45 x 30 100 effluent savings = 11 340 8 8 400 x 0.61 x 30 100

Condensate return lines

The subject of condensate piping will divide naturally into four basic sections where the requirements and considerations of each will differ. They are: Type of line Pipe sized to carry Drain lines to traps condensate Discharge lines from traps Common return lines Pumped return lines Drain lines to traps flash steam flash steam pumped condensate

The condensate must flow from the steam space outlet to the trap. The steam space and the body of the trap upstream of its orifice will usually be at the same pressure, and flow usually occurs due to the force of gravity. As there is no significant pressure drop between the process and the trap, no flash steam is present in the pipe, and it can be sized to carry condensate only. It should never be assumed that the plant outlet connection indicates the correct size for the trap or condensate pipe, especially in the case of temperature controlled processes where low differentials in pressure can occur across the trap under part-load conditions. Each process will have its own system conditions, and should be treated with these in mind. Refer to the later section 'Stall and the stall point' for further details. Stall is also discussed in Reference Guides: Steam trapping and air venting - TR-GCM-11 Condensate removal from heat exchangers - TR-GCM-23 Long drain lines from plant can fill with steam and prevent condensate getting to the trap. The effect is generally termed 'steam locking'. To minimise this risk, drain lines should be kept short (Fig. 3), first falling vertically wherever possible before any horizontal run, to ensure the trap is below the plant outlet. This also encourages gravitational flow between the outlet and the trap. Float traps are also available with steam lock release devices to alleviate the problem.

Fig. 3 Keep drain lines short

Fig. 4 Trap disharge lines pass condensate, flash, and incondensables Discharge lines from traps These carry condensate, incondensable gases, and flash steam from the trap to the condensate return system (Fig. 4). Flash steam is formed due to the pressure drop across the trap orifice, caused by the difference in pressure between the steam and condensate systems. During start-up of a steam system, condensate will be cool with little or no flash steam, but the condensing rate will be maximum, and air will have to pass with the condensate. Soon, as the system heats up, full steam load may occur, the pressure in the steam space will be at its highest, and the amounts of flash steam released in the discharge line immediately after the trap will be at their greatest. Trap discharge lines are sized on full load conditions because of this. In so doing, the pipe will be adequately sized for start-up loads, including the efficient purging of noncondensable gases. Discharging into flooded return lines Discharging traps into flooded return mains is best avoided, especially from blast action traps draining steam pipelines at saturation temperature. Pumped and rising condensate lines often follow the same route as steam lines, and it is tempting to simply connect drain trap discharge lines into them. The high volume of flash steam released into long flooded lines will violently push the water along the pipe, causing waterhammer, noise, and in the extreme, mechanical failure of the pipe. The solution is to avoid discharging into flooded lines by returning condensate and flash steam in lines that slope at least 1 in 70 down to a vented collecting receiver, from which it can be pumped.

10

Common return lines

Where condensate from more than one trap flows to the same collecting point such as a vented receiver, it is feasible to run a common line into which the individual lines can discharge, as long as certain conditions are met, and the pipework is adequately sized. When connecting to the common line, swept tees will help to reduce mechanical stress and erosion at the joint (Fig. 5).

Steam main

Condensate main

Fig. 5 A swept tee connection

11

If this is not possible, use a float trap to discharge into the flooded line (Fig. 6). The energy dissipated from the relatively small continuous flow from the float trap can usually be absorbed by the flooded line, especially when fitted with a diffuser such as the DF2.

Diffuser

Condensate

Steam

Fig. 6 Float trap with diffuser into a flooded line Another alternative is to use a thermostatic trap which holds back condensate until it cools below the steam saturation temperature thus reducing the amount of flash steam formed (Fig. 7). To avoid waterlogging the steam main, the use of a generous collecting pocket on the main, plus a cooling leg of 2 to 3 m of unlagged pipe to the trap is essential. The cooling leg gives storage for condensate while it is cooling to the discharge temperature. If there is any danger of waterlogging the steam main, do not use this method. Always consult expert advice from Spirax Sarco if in any doubt.

Diffuser

Condensate

Steam

Thermostatic trap set with cooling leg

Fig. 7 Thermostatic trap with cooling leg into a flooded line 12

Temperature controlled plant with steam traps draining into flooded lines Take care if condensate from steam traps on temperature controlled plant is discharged into flooded lines. The back pressure could have a derogatory effect on the performance of the trap and the efficiency of the process (Fig. 8).

Heat exchanger

Heat exchanger

Steam trap

Flooded common line

Pumping trap Non - flooded common line

Fig. 8 Discharge from steam traps into non-flooded lines if possible. Discharge lines at different pressures However, condensate from more than one temperature controlled process may join a common line as long as this line is: a) designed to slope in the direction of flow to a collection point b) sized to cater for the cumulative effects of any flash steam from each of the branch lines at full load. The concept of connecting the discharges from traps at different pressures is sometimes misunderstood. If the branch lines and the common line are correctly sized, the pressures downstream of each trap should be virtually the same. However, if these lines are undersized, the flow of condensate and flash steam will be restricted due to a build up of back pressure caused by the increased friction along the pipe. Condensate flow from traps operating at lower pressures will tend to be restricted first. Each part of the discharge piping system should be sized to carry any flash steam present at acceptable velocities. The discharge from a high pressure trap will not interfere with that from a low pressure trap if the discharge lines and common line are properly sized and sloped in the direction of flow. A later section "Sizing of condensate lines" gives further details. 13

Discharge lines from vented pumps

Flash steam may ultimately be separated from the condensate and used in a recovery system, or vented to atmosphere from a suitable receiver (Fig. 9). The residual hot condensate from the latter can be pumped on to a suitable collecting tank such as a boiler feedtank. When the pump is served from a vented receiver, the return line will be fully flooded with condensate having little or no tendency to create flash steam.

Vent

pumped condensate Plant Plant Plant Receiver

Pump

Fig. 9 Condensate recovery from a vented receiver Flow in a pumped return line is intermittent as the pump starts and stops according to needs. The pump discharge rate will be higher than the rate at which condensate enters the pump. It is the pump discharge rate that determines the size of the discharge line. Pumping will be further covered in a later section. Sizing condensate lines As mentioned previously, the four main situations for sizing condensate lines are: Type of line Pipe sized to carry Drain lines to traps Discharge lines from traps Common return lines Pumped return lines condensate flash steam flash steam pumped condensate

14

Sizing drain lines to traps

A simple rule is to make the line to the trap the same size as the trap connections. This presupposes, however, that the trap itself has been sized on sound technical reasoning. A brief synopsis follows: Steam traps basically fall into two distinct areas of application, steam mains or process applications.

From steam mains

The condensate load per trap is affected by various factors such as the size of the pipe, pressure, degree of insulation, ambient temperature, number of traps used along a defined length, position and situation of the pipe. The Technical Reference Guide 'Steam Distribution' (TR-GCM-03), gives information for condensate loads with different sized pipes at various pressures. It is sufficient to consider a condensate load for each drain trap based on 1% of the steam capacity of the main and traps placed every 50 m if insulated, and 5% and 25 m if not. Whatever the size of the main and traps, it is important they are served by an adequately sized drain pocket. As a guide, see below (Fig. 10):

Mains diameter - D Up to 100 mm nb 125 - 200 mm nb 250 mm and above

Pocket diameter - d1 d1 = D d1 = 100 mm d1 = D / 2

Pocket depth - d2 Minimum d2 = 100 mm Minimum d2 = 150 mm Minimum d2 = D

Steam main

d2

d1

Condensate return

Fig. 10

15

The drain line off-take should be at least 25 to 30 mm from the bottom of the pocket for mains up to 100 mm, and roughly a third to centre of the pocket for larger mains. This allows a space below the outlet for dirt and scale to collect, and the bottom may be fitted with a blowdown valve for cleaning purposes. On most drain points, by sizing the trap to pass approx twice the rated design load at the working pressure (minus any back pressure) will allow it to cope with both start-up and running loads. From process applications The method of selecting and sizing the trap depends on whether the process is temperature controlled or not, but in either case the pipe should be sized as below on the worst condition. i) Applications on constant steam pressure Some applications work on a constant pressure supply, such as presses, ironers, ovens, unit heaters, radiant panels, boiling pans etc. When an adequate steam supply is provided, the working pressure tends to remain fairly constant even under varying load conditions. The worst condition will apply at start-up when the steam pressure will tend to drop and the condensation rate is at its highest due to the large difference in temperature between the steam and cold metal.

Air vent

Reducing valve

Jacketed pan

Trap set

Fig. 11 Typical constant pressure application On most constant pressure applications, sizing the trap to pass approx twice the rated design load at the working pressure (minus any back pressure) will allow it to cope with both start-up and running loads.

16

ii) Applications with temperature control If the process is temperature controlled, the system operating parameters and layout need to be considered in greater detail as the heat load may change during normal operation. The steam pressure and condensate load in the heat exchanger will alter as the steam control valve modulates to meet this change, and as the steam pressure reduces, so does the trap's capacity. Take the case of an air heater battery which is designed to heat air from -5oC to 25oC using steam at 3.2 bar (145oC). If the incoming air temperature rises to 5oC, the DT and heat load will be reduced by 30%. The steam temperature will reduce by ratio, and once established, its pressure can be established from steam tables. Steam temp. at full load Steam temp. at no load ie, steam temperature range 30% of range steam temp. at 30 % reduction steam pressure at 105 oC = 145 oC (a) = 25 oC (b) = 120 oC (a - b) = 40 oC (c) = ( [a - b] >< 0.3) = 105 oC (a - c) = 0.2 bar g (from steam tables)

The pressure in the heat exchanger has reduced from 3.2 bar g to 0.2 bar g, and will reduce the trap's capacity. If the trapping device were a float trap and sized on the full load at 3.2 bar g, then it is possible that its capacity may be below that needed at the lower pressure. It is for this reason that it is important to size the float trap on the minimum heat load rather than the full load. Should the steam space pressure reduce enough to approach the condensate pressure, stall will occur and the trapping device is selected and sized on the load at stall point. Not all temperature controlled applications will stall. Stall will not occur if the steam space pressure at the minimum heat load is higher than the condensate back pressure. Whether the trapping device is a float trap, a pumping trap, or a mechanical pump and float trap in combination, will depend on the system operating requirements and the piping infrastructure. The drain line can usually be the same size as the trap especially on shorter lines, but on lines over 5 m, should be checked on the table in Fig. 37 on page 48, against a pressure drop of up to 160 Pa / m. The size of the trap discharge line needs to be determined by a different set of rules, and this is considered next. Stall and its implications on trap sizing is discussed in further detail in a later chapter, and in the Technical Reference Guide "Condensate Removal from Heat Exchangers" (TR-GCM-23) 17

Sizing discharge lines from traps

The section of pipeline downstream of the trap will carry both condensate and flash steam at the same pressure and temperature. This complex situation is called "two phase flow", where the mixture of fluids will have the characteristics of both steam and water in proportion to how much of each component is present. Consider this by example where 10% of condensate forms flash steam :
Pressure on traps bar g

12 11 10 9 8 7 6 5

Example

4 3 2 1

Fig. 12 Quantity of flash steam from condensate

0 0 0.02 0.06 0.10 0.14 0.18 0.22 kg Flash per kg condensate

As each kg of condensate at 4 bar g passes through the trap, 0.1 kg will become steam at 100C, and 0.9 kg will become water at 100C. However, the respective volumes will depend on the specific volume of each at the pressure in the line (0 bar g). 0.9 kg of condensate will have a volume of = 0.0009 m 0.1 kg of flash steam will have a volume of 0.1 kg >< 1.673 m/kg (spec. vol.at 0 bar g) = 0.1673 m Total volume of 1 kg of the mixture = 0.1682 m Therefore, 0.0009 >< 100 = 0.5% is volume of water in the line 0.1682 and, 0.1673 >< 100 = 99.5% is the volume of flash steam 0.1682

It follows that the flow of fluid through this line will have more in common with steam than water, and it is sensible to size on reasonable steam velocities rather than the relatively small volume of condensate. If lines are undersized, the flash steam velocity and back pressure will increase which can cause waterhammer and reduced trap capacity. 18

2.0

g bar g 1.5 ba 1.0 r g bar g 0.5 bar g 0 ba rg

13

Flash steam pressures

bar 2.5

Steam lines are sized with attention to maximum velocities. Dry saturated steam can safely travel up to 40 m/s. Wet steam needs to travel somewhat slower (15 to 25 m/s) as it carries moisture which can have an erosive and damaging effect on fittings and valves if travelling too fast. Similarly, trap discharge lines can be regarded as steam lines carrying very wet steam, and should be sized on similar velocities. Condensate discharge lines from traps are notoriously more difficult to size than steam lines due to the two phase flow characteristic. In practice, it is impossible to determine what is going on inside the pipe with any certainty. Although the amount of flash steam produced is related to the pressure difference across the trap, there are other factors that will have some bearing on what is happening inside the pipe. For example, If, for some reason, the condensate on the upstream side of the trap is cooler than the saturation temperature, the amount of flash formed after the trap is reduced. This can reduce the size of the line needed. If the line slopes down from the trap to its termination, the degree of slope will have an effect on the flow of condensate, but to what magnitude, and how can this be quantified? On longer lines, radiation losses from the line may condense some of the flash, its volume will decrease along with its velocity, and there may be a case for reducing the line size. But at what point should it be reduced and by how much? If the discharge line lifts up to an overhead return line, there will be times when the lifting line will be full of cool condensate, and times when flash steam from the trap may evaporate some or all of this condensate. Should the line be sized on flash steam velocity or the quantity of condensate? Most processes operate some way below their full load condition for most of their running cycle, which reduces the amount of flash produced for most of the time. Should the designer size on the full load condition when it may not be warranted due to the frequency and small amount of time it occurs? On temperature controlled plant, the pressure differential across the trap will itself change depending on the heat load. This will affect the amount of flash steam produced in the line. Due to the conflicting nature of all the above, an exact calculation of line size would be complex and probably inaccurate. In practice, experience has shown that if trap discharge lines are sized on comfortable flash steam velocities and certain recommendations are adhered to, few problems will arise.

19

Recommendations on trap discharge lines

Correctly sized trap discharge lines that slope in the direction of flow and are open-ended are non-flooded and allow flash steam to pass unhindered over the condensate, (Fig. 13). A minimum slope of 1 in 70 (150 mm drop every 10 m) is recommmended. A simple visual check will usually confirm if the line is sloping - if no slope is apparent it is not sloping enough!
vent easy passage for flash steam

Process easy passage for condensate pumped condensate

1 : 70 slope = 150 mm per 10 m run

vented receiver and pump

Fig. 13 Discharge line sloping 1 : 70 in the direction of flow If unavoidable, non-pumped rising lines (Fig. 14) should be kept as short as possible and fitted with a non-return valve to stop condensate falling back down to the trap. They should discharge into the top of overhead return lines to allow easy passage of flash steam into them. It is sensible to consider slightly larger pipes having lower flash steam velocities to reduce the risk of waterhammer and noise from the steam trying to find passage through the liquid condensate in the rising line. Important: A rising line should only be used where the lowest steam pressure in the process is guaranteed to be higher than the total condensate back pressure. If not, the process will waterlog unless a pumping trap or pump/trap combination is used to provide proper drainage against the back pressure.

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vent 1 : 70 slope = 150 mm per 10 m run

pumped condensate

Process

Flash steam has to pass through the condensate vented receiver and pump

Fig. 14 Keep rising lines short and connect to the top of return lines Return lines themselves should also slope down and be nonflooded (Fig. 14). To avoid flash steam occurring in flooded return lines, hot condensate from trap discharge lines should drain into vented receivers (or flash vessels where appropriate), from where it can be pumped on to its final destination via a flooded line at a lower temperature. The Condensate pipe sizing chart (Fig. 15). The condensate pipe sizing chart can be used to size any type of condensate line. Lines containing two-phase flow, such as trap discharge lines, are selected according to the pressures either side of the trap. The chart works around acceptable flash steam velocities according to the pipe size and percentage flash steam formed. The chart can be entered on lower temperatures than the steam saturation temperature, such as may be the case when using thermostatic steam traps for condensate discharge.

21

Pipe sizes can be estimated for pumped lines containing condensate below 100C, as shown by example 5. Also, short drain lines to traps (less than 5 m) can be determined in a similar way. Note: in the case of pumped lines, the pressure drop and velocity must always be checked by referring the condensate flowrate to the pipe size against the table provided in Fig.37 (pages 48 and 49). The chart is used to size trap discharge lines on full load conditions. It is not necessary to consider any oversizing factors for start-up load or the removal of non condensable gases. Using the chart On the lower chart, establish the point where the steam and condensate pressures meet. Move vertically up to the upper chart to choose the selected condensate rate. If the discharge line is falling (non-flooded) and the selection is on or between lines, choose the lower line size. If the discharge line is rising (flooded), choose the upper line size, (Fig. 15). Some examples for sizing trap discharge lines follow. Note: The reasoning behind sizing a trap and a discharge line is different, and it is perfectly normal for a trap discharge line to be a different size than the trap it is serving. However, the normal ancillary equipment associated with the steam trap set, such as the isolation valves, strainer, trap testing chamber, and check valve can be the same size as the trapping device whatever the discharge line size. A condensate line sizing chart is provided for photocopying in Appendix 1 (page 81).

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100,000 50,000

500

400

350

300

250

200
150 100 80

20,000 10,000 5,000

Condensate rate kg/h

65 50 40
Condensate line size mm

32

2,000 1,000 500

25
5

20 15 10

200 100 50

20 10

1 3 4 6 2

Steam system pressure bar g

50 30 20 15 10 5 2 1 0.5 0
1 4 3 6 2

250
Steam temperature C

30 20 10 5 4 3 2 1 0.5 0

Condensate system pressure bar g

200 180 160 140 120 100

Fig. 15 Condensate line sizing chart 23

Example 1

A steam trap passing a full load of 1 000 kg/h at 6 bar g saturated steam pressure through a sloping discharge line down to a flash vessel at 1.7 bar g.

6 bar

H.P. steam Shell and tube heat exchanger

L. P. steam Float trap set 25 Discharge line being sized Flash vessel 1.7 bar

Fig. 16 Example 1 - non-flooded pressurised trap discharge line As the discharge line is non-flooded, the lower figure of 25 mm is selected from the chart.

24

Example 2

A steam trap passing a full load of 1000 kg/h at 18 bar g saturated steam pressure through a discharge line rising 5 m up to a pressurised condensate return line at 3.5 bar g.

3.5 bar 18 bar H.P. steam Air vent

32 5m

Float trap SA control valve acting as air vent and condensate drain on start up Discharge line being sized

Fig. 17 Example 2 - flooded trap discharge line Add the 0.5 bar static pressure (5 m head) to the 3.5 bar condensate pressure to give 4 bar g back pressure. As the discharge line is rising and thus flooded, the upper figure of 32 mm is selected from the chart.

25

Example 3

A steam trap passing a full load of 200 kg/h at 2 bar g saturated steam pressure through a sloping discharge line falling down to a vented condensate receiver at atmospheric pressure.

2 bar H.P. steam

Plate heat exchanger To high level condensate return line Discharge line being sized 20 Vent

25

Fig. 18 Example 3 - non-flooded vented trap discharge line As the line is non-flooded, the lower figure of 20 mm is selected from the chart.

26

Example 4

A pumping trap passing a full load of 200 kg/h at 4 bar g saturated steam space pressure through a discharge line rising 5 m up to a non-flooded condensate return line at atmospheric pressure.

4 bar H.P. steam

5m Air flow 25

Discharge line being sized

Fig. 19 Example 4 - flooded trap discharge line The 5 m static pressure contributes the total back pressure of 0.5 bar g. As the trap discharge line is rising, the upper figure of 25 mm is selected from the chart.

27

Example 5

The automatic condensate pump shown in example 3 can also have its discharge line sized by the chart. The pump discharge rate is sized on 6 times the maximum expected inlet rate, in this case 6 >< 200 kg / h = 1 200 kg / h.

Vent

Condensate in

Sloping non-flooded return line

25 Pumped condensate out Discharge line being sized

Fig. 20 Example 5 - pumped discharge line Because the condensate will have lost its flash steam content to atmosphere via the receiver vent, the pump will only be pumping liquid condensate. In this instance, it is only necessary to use the top graph as shown in the example. As the line from the pump is rising, the upper figure of 25 mm is chosen. A useful tip for lines of 100 m or less is to choose the discharge pipe the same size as the pump. Also refer to the later section on condensate pumping for further details. Example 6 A balanced pressure thermostatic steam trap draining a hot table operating on a constant steam pressure of 2.6 bar g discharges condensate at 20C below saturation temperature from a 2 metre cooling leg up to an overhead non-flooded condensate line 2 metres above the trap. The full load is 100 kg/h. The saturation temperature of steam at 2.6 bar g is 140C, so the discharge temperature from the trap will be around 120C. The chart is then entered on the temperature scale at 120C rather than the pressure scale. The 2 m back pressure contributes the total back pressure of 0.2 bar g. As the trap discharge line is rising, the upper figure of 15 mm is selected.

28

Sizing common return lines

It is sometimes required to connect several trap discharge lines from separate processes into a common return line. Problems will not occur if the following considerations are met: a) the common line is not flooded and slopes in the direction of flow to an open end or a vented receiver, or a flash vessel if the conditions allow. b) the diameter of the common line is sized on the cumulative sizes of the branch lines. The common line size downstream of two connected trap discharge lines is the root of the sum of the squares of the connected lines. The example shows three heat exchangers, each separately controlled and each operated at the same time. Loads shown are full condensate loads and occur at 3 bar g in the steam space. The common line slopes down to the flash vessel at 1.5 bar g situated in the same plant room. Condensate in the flash vessel falls via a float trap down to a vented receiver from where it is pumped direct to the boiler house. The trap discharge lines are sized on full load with steam pressure at 3 bar g and condensate pressure of 1.5 bar g, and as each is not flooded, the lower line sizes are picked from the graph. Line 1 picked as 20 mm, 2 picked as 20 mm, 3 picked as 15 mm Common line for 1+2 Common line for (1+2)+3 = 20+20 = 28 mm = 28+15 = 32 mm

Example

3 bar g

HE 1

3 bar g

HE 2

3 bar g

HE 3

Full load 750 kg/h

Full load 750 kg/h 1" FT14HC

Full load 375 kg/h 1" FT14

Flash steam

1.5 bar g 20 1" FT14HC 20 28 32 15

Fig. 21 Calculating the common line size from the discharge lines

To receiver and pump

29

The theoretical dimension of 28 mm for the common line 1+2 does not exist as a nominal bore in commercial pipe sizes. The internal diameters of pipes can be larger or smaller than the nominal bore depending on the pipe schedule. Eg. for a DIN 2448 steel pipe, the internal diameter for a 25 mm nb is about 28.5 mm, while that for a 25 mm nb Schedule 40 pipe is about 26.6 mm. For most practical purposes, a 25 mm nb pipe may be comfortably selected. If in doubt, seek expert advice. Example Further example of calculating the common line size (Fig. 22)

40 A

15 B C ?

15 D E ?

15 F G ?

15 H J ?

32 K L ?

Fig. 22 Trap discharge lines connecting to a common line Line A B C D E F G H J K L Size (mm) 40 15 Commercial size (mm) 40 15 = 42.7 40 15 = 45.2 40 15 = 47.6 50 15 = 49.9 50 32 = 59.3 65

402+152
15

152+42.72
15

152+45.22
15

152+47.62
32

322+49.92

The commercial pipeline size is taken as the nearest available to the calculated size. This may mean downsizing in certain instances, but this will not normally cause problems in practice due to the diversity of loads in the other lines. 30

Sizing pumped return lines

Flash steam, separated from the condensate, will be used in a flash steam recovery system or simply vented to atmosphere. The remaining hot condensate should be pumped to the boiler house where its energy content and purity can be used to good effect. The pumped return line will only carry condensate but at lower velocities (typically 1 - 2 m/s) than those experienced in the trap discharge and common lines. As seen in example 5, the pump discharge line can be selected from the condensate line sizing chart, or often simply sized the same size as the pump outlet. Refer to the following section "Condensate Pumping" for more detail. It is important to remember that the flow in a pumped line is intermittent, as the pump usually cycles. The instantaneous flowrate while the pump discharges is higher than that which enters the pump. It is the instantaneous discharge figure that has to be considered on discharge lines.

Pumped lines longer than 100 m

Water in lines longer than 100 m will develop larger forces of inertia due to the larger mass of water that is moved during the pumping stroke. It is advisable to add the effects of inertia to pressure drop calculations on sizing these longer lines when mechanical pumps are used. Refer to the section 'longer delivery lines' at a later stage in this document for further details. As a general rule, the pipe should be at least one size larger than the pump outlet check valve.

Mechanical pump Additional check valve 1 pipe length from pump

Line over 100 m

Fig. 23 An additional check valve 1 pipe length from the pump body to reduce the effect of backflow At the end of the pumping stroke, the condensate will tend to keep moving and can often cause a vacuum to be created downstream of the pump outlet check valve. As the momentum of the condensate falls, the vacuum creates a sudden backflow onto the check valve which can, in extreme cases, cause severe waterhammer and noise. An additional check valve fitted 1 pipe length after the pump outlet check valve tends to dampen the effect and protect the pump check valve from damage (Fig. 23). 31

If there is any choice, it is always best to lift immediately after the pump to a height allowing a gravity fall to the end of the line (Fig. 24). If the fall is enough to overcome the frictional resistance of the pipe (Fig. 26), then the only back pressure onto the pump is that formed by the initial lift. A vacuum breaker can be installed at the top of the lift not only to assist the flow along the falling line but also to prevent any tendency for backflow at the end of the stroke.

Vacuum breaker

fall fall due to obstruction

Automatic air vent

Mechanical pump

Fig. 24 best choice - lift after the pump Should the falling line have to fall anywhere along its length to overcome an obstruction, then an automatic air vent fitted at the highest point will assist flow around the obstruction (Fig. 24).

Tank

Mechanical pump

Fig. 25 alternative choice - lift after the pump to a break tank

32

Alternatively, any question of back pressure caused by the horizontal run can be entirely eliminated by an arrangement as in Fig. 25 in which the pump simply lifts into a breaktank. The pipe from the tank should fall in accordance with the table in Fig. 26.
Pipefall need to overcome pipe friction 25 mm in 15 m 25 mm in 10 m 25 mm in 8 m 25 mm in 6 m 25 mm in 5 m 25 mm in 4 m 25 mm in 3 m 25 mm in 2 m 25 mm in 1.75 m* 25 mm in 1.5 m 25 mm in 1 m 48 59 69 79 86 93 113 140 152 165 206 140 177 204 231 256 279 338 419 454 490 612 303 381 442 503 553 598 730 907 984 1 061 1 324 580 694 800 907 1 007 1 093 1 329 1 655 1 793 1 932 2 404 15 20 25 32 Pipe size (DN mm) 40 907 1 134 1 310 1 487 1 642 1 778 2 168 2 694 2 923 3 152 3 923 50 1 950 2 449 2 834 3 220 3 551 3 878 4 672 5 851 6 327 6 804 8 482 65 3 538 4 445 5 148 5 851 6 441 7 030 8 527 10 614 11 498 12 383 15 422 80 5 806 7 257 8 391 9 525 10 568 11 521 13 925 17 327 18 756 20 185 25 174 100 12 610 15 680 18 159 20 638 22 770 24 811 30 073 37 421 40 573 43 726 54 431 125 22 906 28 576 33 089 37 602 41 821 45 994 54 073 68 039 73 708 79 378 99 019 150 37 284 46 492 53 862 61 223 67 538 73 571 89 356 111 128 120 426 129 725 161 476 *(1:70) Litres of water per hour

Fig. 26 Pipe fall to overcome frictional losses Vented pumps, pumping traps and pump-trap installations

Discharge lines from pumps vented to atmosphere are sized on the discharge rate of the pump. Condensate passing through pumping traps and pump/trap combinations in closed loop applications will often be at higher pressures and temperatures and flash steam will be formed in the discharge line. Because of this, discharge lines from pumping traps (such as the APT14), and pump/trap combinations (such as an MFP14 and FT float trap) are sized on the trapping condition at full load and not the pumping condition, as the line has to be sized to cater for flash steam. Sizing on flash steam will ensure the line is also able to cope with the pumping condition.

33

Condensate pumping from vented receivers

In nearly all steam using plants, as much condensate as possible should be returned to the boiler house to use again. Even if gravity drainage can be used from the plant to the boiler house, often the condensate must be lifted into a boiler feedtank. Before looking at the types of pump available for condensate pumping, it may be helpful to discuss some basic pumping terminology. Pumping terminology Vapour pressure. This term is used to define the pressure corresponding to the temperature at which conversion of a liquid into vapour takes place. In other words, it is the pressure at which a liquid will boil i.e. At atmospheric pressure, water will boil at 100C At a pressure of 7 bar g, water will boil at 170.5C At a pressure of 0.75 bar abs, water will boil at 92C The vapour pressure is a very important consideration when pumping condensate. Condensate is usually close to its boiling point, which may cause difficulties where a centrifugal pump is concerned. This is because as the condensate is drawn into the pump impeller, it is accelerated and so experiences a drop in pressure. If this drop in pressure takes the condensate below the vapour pressure or saturation pressure for its temperature, the condensate will boil and some of the condensate will be released as flash steam bubbles. As the bubbles are carried along within the water, they reach a region of increased pressure, as they leave the pump impeller. This increased pressure brings the steam bubbles back above the saturation pressure causing the bubble to implode rapidly. If this occurs while next to a solid surface, the forces exerted by the liquid rushing in to fill the spaces creates very high localised pressures. This is known as cavitation and is capable of doing a great deal of damage to a pump impeller and housing within a short period of time. It also creates noise, similar to that of gravel rotating in the pump. It is often recommended that electrical pumps are not used to pump condensate at temperatures above 100C. Some will have limits as low as 94C or 96C, depending on the design of the pump and the suction head provided by the receiver. Head (h) Head is a term used to describe the potential energy of a fluid at a given point. There are several ways that head can be measured.

34

Pressure head (hp). Pressure head is simply the fluid pressure at the point in question. e.g. A pump is required to discharge against a pressure head of 3 bar g. The pump fills from a pressure head of 0.1 bar g. Where water is the fluid, a 1 bar pressure head is equivalent to approximately 10 m of static head.

0.1 bar g

Pump inlet

3 bar g

Fig. 27 Pressure head Static head (hs). Static head is the equivalent vertical height of fluid above the point in question. The following example best explains the measure of static head. The pump inlet in Fig. 28 is subjected to a static head (known as the suction or filling head) of 1 m, and discharges against a static head (known as the static delivery head) of 30 m. Note that in this case, the water in the bottom of the header tank is above the pump inlet (this situation is called a flooded suction), With an electrical pump the suction head is subtracted from the static delivery head, to give the net static head against which the pump has to work. With a mechanical displacement pump (Fig.29), the filling head simply provides the energy to fill the pump, and has no effect on the head against which the pump has to operate.
Collecting tank

Net static head 29 m Header tank Static delivery head 30 m

Static suction head 1m

Pump inlet

Fig. 28 Net static head for an electrical pump 35

Collecting tank

Pump receiver

Condensate flow hs = net static head

flooded suction head

Fig. 29 Net static head for a mechanical pump Friction head (hf). The friction head is more accurately defined as the pressure loss due to friction, and is the head required to actually move the liquid along the pipeline, and, in simple terms, increases proportionately to the square of the velocity. Pressure loss can be found from tables showing the liquid flowrate, the pipe diameter and the pipe length. To be precise, the resistance to flow encountered by the various pipe line fittings must also be taken into account. Tables are available to calculate the equivalent length of straight pipe for various pipe fittings. This extra 'equivalent length' for pipe fittings is then added to the actual pipe length to give a 'total equivalent length'. However, in practice, if the pipe is correctly sized, it is unusual for the pipe fittings to represent more than an additional 10 % of the actual pipe length. A general rule which can be applied is: Total equivalent length ( le ) = Actual length + 10 % Within this reference guide, a figure of 10 % will be used as the extra equivalent length considered for calculating pressure loss due to friction. Tables are available which give head loss per metre of pipe for various flowrates, pipe diameters, and velocities. The standard S.I. units are Pascals per metre (Pa/m) or millibars per metre (mbar/ m). An example of such a table is given in Fig. 32 page 40. 36

Total delivery head (hd). The total delivery head hd against which the pump needs to operate is the sum of : Pressure required to raise the water to the desired level hs Pressure required to move the water through the pipes hf Pressure in the condensate system hp ie Total delivery head, hd = hs + hf + hp Electrical centrifugal condensate pumps Pump operation. Centrifugal pumps utilise centrifugal force, which imparts a high velocity to the liquid (condensate) being pumped. Pressure energy is obtained by the rotation of an impeller fitted within a casing. Liquid enters the pump and is directed to the centre of the rotating impeller vanes. As the impeller rotates, the liquid is passed along the impeller vanes and increases in velocity. Pump application. The electrical pump is well suited to applications where large volumes of liquid need to be moved. Electrical pumps are usually built into a unit, often referred to as a condensate recovery unit (CRU). A CRU will usually include: A receiver. A control system operated by probes or floats. One or two pumps. The instantaneous flow from the CRU can be up to 1.5 times greater than the rate at which condensate returns to the receiver. It is this pumping rate that must be considered when calculating the friction loss in the discharge line. On twin pump units, a 'cascade' control system may also be employed which allows either pump to be selected as the 'lead' pump and the other as a 'stand-by' pump to provide back up if the condensate returning to the unit is greater than one pump can handle. This control arrangement also provides back up in the case of the one pump failing to operate; the condensate level in the tank will increase and bring the second pump into operation. Cascade type units usually pump at a rate of 1.1 times the return rate to the receiver, allowing a smaller discharge line to be considered. It is very important that the manufacturer's literature is read regarding the discharge pumping rate. Failure to do so could result in undersizing the pump discharge pipe work.

37

Vent Condensate in Condensate in

Level sensor

Receiver

Condensate out

Overflow with "U" seal

Electric pump

Fig. 30 A typical electrical condensate recovery unit (CRU) Sizing an electrical condensate recovery unit To size an electric condensate recovery unit, it is necessary to know: The amount of condensate reaching the receiver in kg/h at running load. The temperature of the condensate. This must be below the manufacturer's specified ratings to avoid cavitation, however, manufacturers usually have different impellers to suit different temperature ranges, eg. 90C, 94C and 98C. The total discharge head required. (Will need to be calculated from the site conditions) The pump discharge rate in order to size the return pipework. (Be sure to read the manufacturer's data properly to determine this).

38

Example Temperature of condensate Condensate to be handled Static lift ( hs ) Length of pipe work Condensate back pressure = = = = = 94C 1 800 kg/h 30 m 150 m friction losses only ( hf)

Using the data below, an initial selection of a condensate recovery unit can be made from the manufacturer's sizing chart, such as the one in Figure 31. From the chart, CRU 1 should be the initial choice subject to frictional losses in the delivery pipework.
Pump 35 delivery head in metres 30

CRU 1

25 CRU 2 20

15 CRU 3 10

5 100 200

1800 2 000 300 400 500 1 000 Condensate to be handled at 94C kg/h

Fig. 31 Typical CRU sizing chart Sizing the discharge pipework for an electric condensate recovery unit

From the chart in Fig. 31, it can be seen that CRU 1 is actually rated to handle 2 000 kg/h of condensate. Reading the manufacturer's data shows that the CRU will actually pump 1.5 times the maximum return rate shown on the sizing chart. i.e.: 1.5 x 2 000 kg/h = 3 000 kg/h This ensures start-up loads can be handled without overflowing, and this is what the discharge pipe work must be sized on. As in the earlier example it is now possible to determine the optimum size for the return line. 39

Actual length of pipe work = 150 m Equivalent length of pipe work = 150 m + 10 % = 165 m Fig. 32 Section of typical friction loss table for fully flooded pipelines (flowrates in L/h)
Pressure drop Pa/m mbar/m 95 97.5 100 120 140 0.95 0.975 1.00 1.20 1.40 Pipe size (mm) 32 40 50 1 678 1 699 1 724 1 897 2 059 2 560 2 596 2 632 2 898 3 143 4 860 4 932 5 004 5 508 5 976

15 176 180 184 202 220

20 414 421 425 472 511

25 767 778 788 871 943

65 9 900 10 044 10 152 11 196 12 132

80 15 372 15 552 15 768 17 352 18 792

100 31 104 31 500 31 932 35 100 38 160

From the pressure drop table above, using a 40 mm nb. pipe will allow a flowrate of 3 000 kg/h (L/h) and incur a pressure drop of between 120 and 140 Pa per metre. For this example 128 Pa/m is about right. Therefore the head loss to friction can be calculated; Headloss to friction = = = 128 Pa / m x 165 m 21 kPa approx 2.1 metres

The total delivery head required by the pump is: 30 m (hs) + 2.1 m (hf) = 32.1 metres

The figure of 32.1 metres needs to be checked against the manufacturer's sizing chart for the CRU to confirm that there is sufficient head available - there is in this case, but had the allowable head been exceeded, then the options are to re-calculate using a larger pipe or to select a CRU with a greater lift capacity. Alternatively, it can be seen that the selected CRU1 can pump against a total head (hd) of 35 m. With an actual static head (hs) of 30 m, 5 m are "available" for pipe friction loss (hf). It may be possible to install a smaller pipe and take up a larger friction loss. Reference to the pipe sizing table on page 42 will show that, if the next lower sized pipe is used (in this case 32 mm), the unit friction loss (hf) to pass 3000 kg/h (or 3000 L/h) is 300 Pa/m, and the velocity is just over 1 m/s which is suitable for this application. = 49.5 kPa (or 4.95 m) = hs + h f = 30 + 4.95 m = 34.95 m The conclusion is that 32 mm pipe can be used, as the CRU 1 pump can handle up to 35 m total delivery head. 40 hf is 300 Pa/m x 165 m Therefore, total delivery head

Mechanical condensate pumps

Pump operation. Mechanical pumps consist of a body, into which condensate flows by gravity, containing a float and an automatic mechanism, operating a set of changeover valves. Condensate is allowed to build up inside the body, which raises a float. When the float reaches a certain level, it triggers a vent valve to close and an inlet valve to open to allow steam to enter and pressurise the body to push out the condensate. The condensate level and the float both fall. The steam inlet valve then shuts and the vent valve opens allowing the pump body to refill. Check valves are fitted to the condensate ports to ensure correct directional flow. It should be noted that a receiver is needed when using a pump (Fig. 33), due to its cyclical action. When the pump is discharging it is not filling, so there is a need to store the condensate which is being produced between pumping cycles.

Condensate in

Vent

Steam supply to pump

Receiver

Pumped condensate

Fig. 33 A typical mechanical condensate pump 41

Pump application. Generally, mechanical pumps handle smaller amounts of condensate than electrical pumps. They are however, particularly valuable in situations where: Condensate temperature causes cavitation. Condensate is in vacuum. Space is at a premium. Low maintenance is required. The environment is hazardous, humid or wet. Electrical supplies are not at hand (operated by steam, air or any inert gas). Condensate has to be removed from individual items of temperature controlled equipment which may be subjected to stall conditions. As with electrically driven pumps, they are sometimes, but not always, specified as packaged condensate recovery units. A mechanical condensate recovery unit will comprise a condensate receiver and the pump unit. No additional control system is required as the pump is fully automatic and only operates when needed. This means that the pump is self regulating. Mechanical pumps are, however, a little more involved to size because the flow in the return line is intermittent. The pump cycles as the receiver fills and empties. The instantaneous flowrate while the pump is discharging can often be up to six times the filling rate and it is this instantaneous flowrate which must be used to calculate the size of the discharge pipe. Always refer to the pump manufacturer for data on sizing the pump and discharge line.

42

Sizing a mechanical condensate pump

To size a mechanical condensate pump, the following information is required: The maximum condensate flowrate reaching the receiver. The motive pressure of steam or air available. The selection of steam or air depends on the application and site circumstances. The filling head available. The total back pressure of the condensate system. The sizing of mechanical pumps varies from manufacturer to manufacturer, and is usually based on empirical data, which are translated into factors and nomographs. The following is a typical example on how to size a mechanical pump. (The pipe length is less than 100 m and friction loss is taken as being negligible): Example Condensate load Steam pressure available for operating pump Vertical lift from pump to return piping Pressure in the return piping (piping friction negligible) Available filling head on the pump = = = = = 2 200 kg/h 5.2 bar g 9.2 m 1.7 bar g 0.3 m

Condensate manifold

1.7 bar g return main pressure

Vent

Total plant condensate 2 200 kg/h

Reservoir Filling head 0.3 m

9.2 m lift

Pump

5.2 bar g operating pressure

Fig. 34 Mechanical pump sizing example 43

Calculate the total back pressure (delivery head hd), against which the condensate must be pumped: Total back pressure (hd) = lift (hs)+ condensate pressure (hp) (friction loss neglected as line is shorter than 100 m) lift (hs) cond. pressure (hp) Total = 9.2 m = 1.7 bar g = 17 m head = 9.2 + 17 m = 26 m

Reference to Fig. 35 below shows that a DN50 pump at 5.2 bar g motive pressure will pump 2600 kg/h against a 26 m head, and will thus be the correct choice for this example. Note: the pump is sized on the filling rate.

14
80 m lift 50 m lift 40 m lift

32 m 27 m 26 m
30 m lift 20 m lift 10 m lift 4 m lift

14
80 m lift 50 m lift 40 m lift

32 m
30 m lift

26 m
20 m lift 10 m lift
5000 6000 Flowrate kg/h

13 12 11 10 9 8 7 6 5.2 5 4
Motive pressure bar g

13 12 11 10 9 8 7 6

4
Motive pressure bar g

3 2 1 0
1000 2000 2200 2500 2600 3000 4000

3 2 1 0
1000 2000 2500 3000 4000

DN50 size capacities

5000 Flowrate kg/h

DN80 x DN50 size capacities

Fig. 35 - DN50 MFP 14 pump sizing chart 44

Fig. 36 - DN80 MFP 14 pump sizing chart

4 m lift

5.2 5

Sizing the discharge pipework for a mechanical condensate pump

Below 100 m long, the discharge pipe from a mechanical pump can usually be taken as the same size as the pump body. The frictional resistance of the pipe is relatively small compared to the back pressure caused by the lift and condensate return pressure, and can usually be disregarded. Above 100 m, a general rule would be to select one pipe size larger than the pump outlet check valve. On delivery lines over 100 m, and/or where the condensate flow is near to the pump maximum, it is advisable to check the pipe size to ensure that the total friction loss (including inertia loss) does not increase above that which effects the pump's capability (or installation costs). With 5.2 bar g motive steam and 26 m delivery head, from Fig. 35, for a DN50 pump, Maximum pump capacity = 2 600 kg/h Actual condensate flowrate into pump = 2 200 kg/h again, from Fig. 35, for a DN50 pump, Max. back pressure permissible at 2 200 kg/h = 32 m therefore, max. frictional resistance allowable = 32 - 26 m = 6m (60 kPa) Inertia loss On lines over 100 m, a considerable volume of liquid will be held within the pipe. The sudden acceleration of this mass of liquid at the start of the pump discharge can absorb some part of the pump energy, and this needs to be considered within the friction loss calculation by reducing the allowable friction loss by 50%, thus, Total allowable friction loss Consider delivery pipe length to be 250 m + 10% for additional fittings then, max. frictional resistance allowable / m approx. Taking delivery flowrate as 6 times filling rate = 50 % 60 kPa = 30 kPa = 275 m = 30 kPa 275 m = 109 Pa/m = 6 2 200 = 13 200 kg/h

Longer delivery lines

Referring to Fig. 37 (the table), a frictional resistance of 109 Pa/m reveals that an 80 mm pipe is required to give an acceptable flowrate of 13 200 kg/h. In fact, the table shows that this size pipe will pass about 16 500 kg/h with this frictional resistance. By rising up the '80 mm column', it can be seen that, by interpolation, the flowrate of 13 200 kg/h actually induces a frictional loss of about 72 Pa/m in an 80 mm pipe.

45

Fully loaded pumps and longer lines

Should the condensate filling rate have been near the maximum 2 600 kg/h for the above example, say 2 500 kg/h, then less head is available for friction loss, and progressively less so for longer lines. Sizing on a filling rate of 2 500 kg/h, and a 250 m (+10%) line, referring to Fig. 35, for the DN50 pump, it can be seen that a condensate filling rate of 2 500 kg/h equates to a max. back pressure of about 27 m, hence in this instance, available head left for friction losses frictional resistance allowable = 27 - 26 m = 1 m (10 kPa) = 10 kPa 275 m = 36 Pa / m = 50 % 36 Pa/m

minus allowance of 50% for inertia loss

therefore, max. frictional resistance allowable = 18 Pa / m As before, the discharge pipework has to be sized on the instantaneous flowrate from the pump outlet, which is taken as 6 the filling rate. In this instance, the pipe would have been sized on 6 2 500 kg/h = 15 000 kg/h with a friction loss of 18 Pa/m. Fig. 37 (the table) reveals that this would require a pipe larger than 100 mm to allow the pump to operate within its capability. Although the system would certainly work with this arrangement, it may be more economical to consider a larger pump with smaller pipework.

46

Consideration of a larger pump and smaller pipeline

Fig. 36 reveals that a DN 80 pump under the same conditions of 5.2 bar g motive steam and 26 m back pressure would allow the following friction losses: Back pressure = 26 m

At a filling rate of 2 500 kg/h, max. allowed = 35 m head available for friction loss = 35 - 26 m = 9 m (90 kPa) 90 kPa over 250 m and inc. inertia loss max. frictional resistance allowable = 50 % 90 250 = 180 Pa/m

Fig. 37 (the table) shows that an 80 mm pipe will accommodate 21420 kg/h with a friction loss of 180 Pa/m. Hence, in this instance, the larger pump will comfortably allow a pipe two sizes smaller than that for the smaller pump. Always check that velocity is within recommendations. The 80 mm pipe will handle the above condition at just under 1 m/s, and is therefore suitable. The DN80 pump would cost about 10% more than the DN50 pump, but these costs could well be recovered with the difference in installation costs on longer delivery lines between an 80 mm and 100+ mm pipe plus fittings and insulation etc.

47

Fig. 37 - Flow of water in heavy steel pipes (with velocities)

kg/h 15 mm Pa/m 10 12.5 15 17.5 20 22.5 25 27.5 30 32.5 35 37.5 40 42.5 45 47.5 50 52.5 55 57.5 60 62.5 65 67.5 70 72.5 75 77.5 80 82.5 85 87.5 90 92.5 95 97.5 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 mbar/m 0.1 0.125 0.15 0.175 0.2 0.225 0.25 0.275 0.3 0.325 0.35 0.375 0.4 0.425 0.45 0.475 0.5 0.525 0.55 0.575 0.6 0.625 0.65 0.675 0.7 0.725 0.75 0.775 0.8 0.825 0.85 0.875 0.9 0.925 0.95 0.975 1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 3 3.2 3.4 3.6 3.8 4 4.2 4.4 50 58 65 68 76 79 83 90 94 97 101 104 112 115 119 122 126 130 130 133 137 140 144 148 151 151 155 158 162 166 166 169 173 176 176 180 184 202 220 234 252 266 281 288 306 317 331 342 353 364 374 385 396 407 20 mm 25 mm <0.15 m/s 119 223 133 252 151 277 162 302 176 328 187 349 198 371 209 389 220 410 230 428 241 446 248 464 259 479 266 497 277 511 284 526 292 540 299 558 306 572 317 583 324 598 331 612 338 626 346 637 353 652 356 662 364 677 371 688 378 698 385 709 389 724 396 734 403 745 407 756 414 767 421 778 425 788 472 871 511 943 547 1015 583 1080 619 1141 652 1202 680 1256 713 1310 742 1364 767 1415 796 1465 821 1512 846 1559 871 1602 893 1645 918 1688 940 1732 32 mm 0.15 m/s 490 554 616 670 720 770 814 857 900 940 979 1015 1051 1087 1123 1156 1188 1220 1249 1282 1310 1339 1368 1397 1422 1451 1476 1505 1530 1555 1580 1606 1627 1652 1678 1699 1724 1897 2059 2210 2354 2488 2617 2740 2855 2970 3078 3182 3287 3388 3492 3578 3672 3744 40 mm 756 853 943 1026 1105 1177 1249 1314 1379 1440 1498 1555 1609 1663 1717 1768 1814 1865 1912 1958 2002 2048 2092 2131 2174 2218 2257 2297 2336 2372 2412 2448 2488 2524 2560 2596 2632 2898 3143 3373 3589 3780 3996 4176 4356 4536 4680 4860 5004 5148 5292 5436 5580 5724 50 mm 1447 1634 1807 1966 2113 2254 2387 2513 2632 2747 2858 2966 3071 3175 3272 3370 3463 3553 3636 3744 3816 3888 3996 4068 4140 4212 4284 4356 4464 4536 4608 4680 4716 4788 4860 4932 5004 5508 5976 6408 6804 7200 7560 7920 8244 8568 8892 9180 9504 9756 10044 10332 10584 10836 65 mm 2966 3348 3708 4032 4320 4608 4860 5112 5364 5616 5832 6048 6264 6480 6660 6876 7056 7236 7416 7596 7776 7920 8100 8280 8424 8568 8748 8892 9036 9180 9324 9468 9612 9756 9900 10044 10152 11196 12132 12996 13824 14580 15336 16056 16740 17388 18000 18612 19224 19800 20340 20880 21420 21924 80 mm 4644 5220 5760 6264 6732 7164 7596 7992 8352 8712 9072 9396 9720 10044 10368 10656 10944 11232 11520 11808 12060 12312 12600 12852 13068 13320 13572 13788 14040 14256 14472 14724 14940 15156 15372 15552 15768 17352 18792 20160 21420 22644 23760 24876 25920 26928 27900 28836 29772 30636 31500 32364 33156 33984 100 mm 0.3 m/s 9432 10656 11736 12744 13680 14580 15408 16200 16956 17712 18432 19116 19764 20412 21024 21636 22212 22788 23364 23904 24444 24984 25488 25992 26496 27000 27468 27972 28440 28872 29340 29772 30240 30672 31104 31500 31932 35100 38160 40680 43200 45720 47880 50400 52200 54360 56160 58320 60120 61920 63720 65160 66960 68400

0.5 m/s

1 m/s

1.5 m/s

2 m/s

48

Fig. 37 - Flow of water in heavy steel pipes (with velocities)

kg/h 15 mm Pa/m 440 460 480 500 520 540 560 580 600 620 640 660 680 700 720 740 760 780 800 820 840 860 880 900 920 940 960 980 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 mbar/m 4.4 4.6 4.8 5 5.2 5.4 5.6 5.8 6 6.2 6.4 6.6 6.8 7 7.2 7.4 7.6 7.8 8 8.2 8.4 8.6 8.8 9 9.2 9.4 9.6 9.8 10 11 12 13 14 15 16 17 18 19 20 407 414 425 432 443 450 461 468 479 486 493 500 511 518 526 533 540 547 554 562 569 576 583 590 598 605 612 619 623 655 688 716 745 770 799 824 850 871 896 20 mm 940 961 983 1004 1026 1048 1066 1087 1105 1123 1145 1163 1181 1199 1217 1235 1249 1267 1285 1303 1318 1336 1350 1364 1382 1397 1411 1429 1444 1516 1588 1652 1717 1782 1840 1901 1955 2012 2066 25 mm <1 m/s 1732 1771 1811 1850 1886 1926 1962 1998 2034 2070 2102 2138 2171 2203 2236 2268 2300 2333 2362 2394 2423 2452 2480 2513 2542 2567 2596 2624 2653 2786 2912 2894 3154 3269 3380 3485 3589 3708 3780 32 mm 1 m/s 3744 3852 3924 4032 4104 4176 4212 4356 4428 4500 4572 4644 4716 4788 4860 4932 5004 5076 5112 5184 5256 5328 5400 5436 5508 5580 5616 5688 5760 6048 6300 6588 6840 7128 7308 7560 7776 7992 8208 40 mm 5724 5868 5976 6084 6228 6372 6480 6588 6732 6840 6948 7056 7164 7272 7380 7488 7560 7704 7812 7884 7992 8100 8172 8280 8388 8460 8568 8640 8748 9180 9612 10008 10404 10764 11124 11484 11808 12132 12456 50 mm 10836 11088 11340 11592 11808 12060 12276 12492 12708 12924 13140 13356 13572 13788 13968 14184 14364 14544 14760 14940 15120 15300 15480 15660 15840 16020 16200 16380 16524 17352 18144 18900 19656 20340 21024 21672 65 mm 21924 22464 22932 23436 23904 24372 24840 25272 25740 26172 26604 27000 27432 27828 28260 28656 29052 29412 29808 30204 30564 30924 31284 31680 32004 32364 32724 33084 33408 35064 36720 38160 39600 41040 42480 43920 45000 46440 47520 80 mm 33984 34776 35532 36360 37080 37800 38520 39240 39960 40680 41040 41760 42480 43200 43920 44280 44640 45360 46080 46440 47160 47880 48600 48960 49680 50040 50760 51120 52560 54360 56880 59040 61200 63360 65520 67680 100 mm 2 m/s 68400 70200 71640 73080 74520 75960 77400 78840 80280 81720 83160 84240 85680 3 86760 m/s 88200 89280 90360 91800 92880 94320 95400 96480 97560 98640 99720 100800 101880 102960 104040 109440 114120 4 m/s

49

Lifting condensate from steam mains drain traps

A frequent requirement is to lift condensate from a mains drain trap to a higher level return line (Fig. 38), using the steam pressure within the trap. Pressure can be related to the increase in lift by using the following conversion; 1 m increase in pipework lift = 0.1 bar g back pressure If a head of 5 m produces a back pressure of 0.5 bar, then this reduces the differential pressure available to push water through the trap, although under running conditions the reduction in trap capacity is likely to be significant only where low upstream pressures are being used. It is recommended that a check valve be fitted after any steam trap where there is the case of condensate being lifted. This will prevent condensate from falling back into the trap. At start-up, the steam pressures are likely to be very low for a while, and it is common to find water backing up before the trap. This can lead to waterhammer in the space being drained, if a means of removing the condensate is not provided until sufficient steam pressure is present to overcome the back pressure. The liquid expansion thermostatic trap can often be used, discharging cold condensate to waste but closing to hot condensate, which is then forced through the trap to the return line.

High level condensate return

Steam main

Trap

Liquid expansion trap

Fig. 38 Use of liquid expansion trap

Drain to waste

The discharge line from the trap to the overhead return line is preferably turned over on to the top of the main as shown, rather than simply teed to the underside. This assists operation, because although the riser is probably full of water at start-up, it sometimes contains little more than flash steam once hot condensate under pressure passes through it. If the discharge line were fitted to the bottom of the return line, it would fill with condensate after each discharge and increase the tendency for waterhammer and noise. 50

Contaminated condensate
Occasionally, condensate is discharged from sources where it might have become contaminated by corrosive process liquids, and it becomes unsuitable for use as boiler feed because of the dangers of foaming, scaling or corrosion which can occur in the boiler and in the steam pipes. However, although contaminated, the condensate still carries the same useful heat as clean condensate and could be recovered if proper contamination detection equipment is employed Such systems detect changes in condensate conductivity. When a change occurs then it may mean that the condensate is contaminated. When this happens a dump valve opens, allowing condensate to flow to drain. In some countries, continuous monitoring of condensate is a legal requirement.
Controller

Dump valve

Condensate in

Condensate out

Contaminated condensate Sensor to waste

Drain

Fig. 39 Condensate contamination detection equipment

51

Stall and the stall point

Steam has many benefits when used as a heat medium, some of which are its high heat content, its versatility for use in many different applications, and its ease of control. In temperature controlled plant, a condition commonly called stall can result in poor system performance. With proper arrangements, problems do not occur, but if they do, it is quite a simple matter to put things right. A basic understanding of these problems may benefit the practitioner. The stall condition occurs when the steam space pressure approaches, equals, or is less than the condensate back pressure. This hinders the positive flow of condensate through a steam trap as its capacity reduces relative to the pressure drop across it. It can be identified on a graph known as a stall chart, where it is referred to as the stall point. When stall is inevitable, an active method of condensate removal, such as a pumping trap, will ensure proper drainage of condensate under all load conditions. It is often thought that the steam pressure in a steam / liquid heat exchanger is always enough to force the condensate out. However, the relationship between two process conditions can prevent condensate draining out of a heat exchanger, they are: High condensate back pressure. Low steam pressure in the heat exchanger steam space. When either occurs relative to the other, there can be insufficient pressure difference to move the condensate from the heat exchanger through the trap and into the condensate return line. Condensate will not drain, and the exchanger will begin to fill with water. Symptoms are poor temperature control, waterhammer and noise in the short term, and erosion and corrosion of the heat exchanger in the long term. To maintain good process temperature control and prevent premature mechanical or corrosive failure of heat exchangers, it is essential that condensate is removed from the exchanger as quickly as it forms. The stall cycle The following is an example which shows how the stall situation develops (refer to Fig. 40): When heat exchange occurs, the secondary fluid temperature will rise. This increase in temperature is detected by the control system and the steam valve closes down. The steam pressure falls, and the heat exchanger begins to flood because the back pressure in the condensate return pipe (P2) is greater than the steam pressure after the control valve(P1). 52

To condensate main Temperature sensor

P1

Flow

Heat exchanger

Return

P2 steam trap

Fig. 40 The onset of stall in a heat exchanger with temperature control When the heat exchanger floods, the secondary fluid temperature falls and the flow of steam through the control valve increases. The steam pressure rises (P1 > P2) and discharges the condensate, but leaves the heater filled with steam at a higher pressure than is needed to maintain a stable secondary temperature, as depicted in Figure 41. The cycle then repeats.

To condensate main Temperature sensor P1 sec. flow

P2 steam trap

sec. return

Fig. 41 Continuation of the stall cycle 53

Temperature controlled plant

Condensate drainage to atmosphere Stall can also occur in temperature controlled heaters even when the condensate falls down to a steam trap and down again to a vented receiver or open ended pipe. The back pressure would be atmospheric, but it would be wrong to assume that there would always be enough steam pressure to push the condensate through the steam trap. In this instance, where the secondary control temperature is less than 100C, the steam temperature for some part load conditions will also be lower than 100C (the saturation temperature of steam at atmospheric pressure). Here, the steam space pressure would be in vacuum, making it difficult for condensate to drain from the steam space and pass through the steam trap. A stall condition will exist and special arrangements are needed to drain the condensate. On smaller heat exchangers draining to atmosphere, a simple remedy is to install a vacuum breaker on the steam inlet to the heat exchanger. When vacuum is reached in the steam space, the vacuum breaker opens to allow the condensate to drain down to the steam trap. The trap itself must be placed a discrete distance below the exchanger outlet, and must be sized to pass the condensate stall load on the static head created by the height of the outlet above the trap inlet. The condensate pipe from the trap should slope down so that no further back pressure is exerted on the trap. (Fig. 42)

Temperature control system Vacuum breaker Steam in Secondary flow

Shell & tube Heat exchanger

Static head Secondary return

Condensate out to atmosphere

Fig. 42 Shell & tube heat exchanger draining to atmosphere Often, especially on larger plant, it is usually preferred not to introduce air into the steam space, and the use of a vacuum breaker may not be tolerated. Also, if the condensate lifts after the steam trap up to a higher level, a vacuum breaker cannot assist drainage. In these situations, a pumping trap or pump/trap combination should be used. 54

Closed loop condensate drainage

If stall is inevitable and a vacuum breaker cannot be used, an active method of condensate removal must be used to give good system performance, as shown in Fig. 43. A pumping trap performs as a steam trap if there is sufficient steam pressure in the steam space to overcome the back pressure. If there is not, it acts as a pump. The device is fully self contained and automatic in its operation.
Motive steam line to pump

Secondary flow Steam in Auto air vent Control valve

Balance line

Fig. 43 Shell & tube heat exchanger with pumping trap arrangement

Condensate from heater to APT

The pumping trap is also extremely valuable where there is restricted space below the heater, such as is often the case on air handling units which are often positioned close to the plant room floor. Fig. 44 shows an example draining single and multi- heater batteries to avoid both freezing and corrosion of the coils.

Steam in

Steam in

Heater batteries

Air flow

APT14s

Motive line trap set

Fig. 44 Pumping traps on heater batteries with low suction heads When a pumping trap arrangement is used, condensate will always be removed from the heater under all pressure conditions, ensuring maximum system efficiency at all times, with no escape of flash steam in the plant room. 55

Where plant capacity is too large for the pumping trap, it can be replaced by a separate pump and steam trap in combination, such as that shown in Fig. 45. A mechanical fluid pump is dedicated to a single heater, connected so that the pump chamber, piping, and the steam side of the heater tubes form a common steam space. When the steam pressure is sufficiently high, condensate flows from the steam space and through the pump body and steam trap and away. When the pressure is lowered as the control valve closes down, condensate fills the pump chamber. Admittance of motive steam at high pressure is triggered, pushing condensate out of the chamber and away through the trap. The pump exhaust line is connected to a reservoir and acts as a balance pipe when the pump is filling. The small amount of exhaust steam is then contained within the system, and pumping occurs with no waste of steam to atmosphere, making the system energy efficient, and the plant room free from flash steam.

Secondary flow

Steam in Shell & tube Heat exchanger

Motive steam to pump Air vent & check valve Secondary return

Reservoir

Pump Trap Condensate against a back pressure

Fig. 45 Shell & tube heat exchanger with pump and trap arrangement

56

Determining the stall point on temperature controlled plant

In any heat exchanger, the heat flow Q, at any time, may be . expressed by Q = U . A . DTm. where, . Q is heat transfer in watts U is the overall heat transfer coefficient (W/mC) A is the area of the heat transfer surfaces (m) DTm is the mean temperature difference between steam and water (C) If the heat flow in a steam/water or steam /gas heat exchanger is to be varied, a thermostatic control valve changes the steam flow. This leads to a change of pressure in the steam space, and so too a change in temperature. This immediately changes the value of DTm in the heat flow equation. Since A and U virtually . remain constant, the heat flow Q varies directly with DTm. For maximum heat load, DTm must be at its greatest value, ie maximum steam temperature (and pressure) and minimum secondary temperature with secondary fluid flow at its greatest. For no load, DTm must be zero, ie the steam temperature must be the same as the fluid leaving the heat exchanger. For 50% load, DTm must be 50% of maximum DTm and so on. This allows two straight lines to be drawn on a chart (see Fig. 46), A - B and C - B which are furthest apart at full load, and meet at no load. The upper line A - B represents the changing steam temperature (and pressure), and the lower line C - B represents the secondary inlet fluid temperature. The chart can relate any secondary inlet temperature and corresponding steam temperature to the heat load. If a horizontal line is drawn, D - E, representing the pressure downstream of the trap, it is possible to see when the steam pressure approaches the back pressure and the system starts to stall. Further reduction in load increases the waterlogging.

Using the stall chart

Q. Why use a stall chart? A. It is a simple way of telling whether a steam trap or pumping trap is needed for the application! In order to select and size the trapping device correctly, the following information needs to be known: Steam flowrate at full load. Steam pressure in the steam space at full load. System back pressure. Secondary inlet temperature at full load. Secondary outlet temperature at full load. Minimum load condition

57

Example 1

Steam flowrate at full load Steam pressure in heater at full load (A) Condensate system back pressure (E) Inlet secondary medium temperature (C) Outlet secondary medium temperature (B) Minimum load condition (% of full load)

= 600 kg/h = 7 bar g = 2 bar g = 25C = 80C = 40 % = 240 kg/h

Plot the above information on the stall chart (Fig. 46) in the following sequence. 1. Plot the incoming secondary inlet temperature (C) and outlet secondary temperature (B) to give the secondary temperature line C - B. 2. Plot the full load steam pressure (A) on the left side of the chart, and connect the line A - B. 3. Plot the condensate back pressure (point E) 4. Plot the point where the line A - B intersects with the system back pressure line (D - E), and drop straight down to the bottom of the chart to determine the percentage load (F) at which the stall condition will occur. Any loads lower than 60% will require the use of a pump or pumping trap. From the chart, the stall condition is at 60 %. From the maximum steam load of 600 kg/h, this will be approximately 360 kg/h. As the expected minimum load condition of 40 % is lower than the stall load, a pumping trap will be required to provide proper and complete drainage. NOTE: if the minimum load were higher than the stall load, (at say 70 %, ie 30% reduction) then the system will never stall. Here, a steam trap only is needed, and is sized on the minimum load condition, ie 70 % of 600 kg/h = 420 kg/h, at the pressure differential across the trap at this point - see below to establish this: Steam temp. at full load Steam temp. at no load ie, steam temperature range 30% of range steam temp. at 30 % reduction steam pressure at 140 oC condensate back pressure Minimum load diff. pressure = 170C = 80C = 90C = 30C = 140C = 2.6 bar g = 2.0 bar g = 0.6 bar (a) (b) (a - b) (c) = ( [a - b] x 0.3) (a - c) (from steam tables)

Float trap sized to pass 420 kg/h with 0.6 bar diff. pressure. 58

Example 2

The stall load can also be calculated mathematically. This may be best explained using the information from the previous example: (Equivalent back pressure temp) - (Outlet secondary temp) (Full load steam space temp) - (Outlet secondary temp) = 134 - 80 170 - 80 Percentage stall load= 60 % Actual stall load = 60 % x 600 kg/h = 360 kg//h As the 40% minimum load (240 kg/h) is going to be lower than the 60 % stall load (360 kg/h), the system will require a pumping trap or pump for correct condensate drainage. Correct selection and sizing procedure of condensate removal devices is further explained in the Spirax Sarco Technical Reference Guide TR-GCM-23 'Draining condensate from heat exchangers'.

Example 3

An easier way of determining whether a system will stall and whether a steam trap or pumping trap is needed is achieved by the APT14 pumping trap computer sizing program, which accurately plots a bespoke stall chart for any installation. For further details please contact any local Spirax Sarco office, or sales engineer.

59

T C

Pressure - bar absolute (vacuum)

F 90 80 70 60 50 40 30 20 10 0

100

Percentage load

Fig. 46 A typical stall chart

60

Pressure - bar absolute (vacuum)

39.0 33.0 27.0 22.0 18.0 14.5 11.6 9.0 7.0 5.2 3.8 2.6 1.7 1.0 0.4 0 0.7 0.5 0.3 0.2 0.12 0.07 0.05

250 240 230 220 210 200 190 180 A 170 160 150 140 D 130 120 110 100 90 80 70 60 50 40 30 C 20 10 0 -10 -20 -30 -40 -50

T C

Steam supply pressure (7 bar g)

Stall point Back pressure (2 bar g)

Secondary outlet temperature (80C)

250 240 230 220 210 200 190 180 170 160 150 140 130 120 110 100 90 80 70 60 50 40 30 20 10 0 -10 -20 -30 -40 -50

39.0 33.0 27.0 22.0 18.0 14.5 11.6 9.0 7.0 5.2 3.8 2.6 1.7 1.0 0.4 0 0.7 0.5 0.3 0.2 0.12 0.07 0.05

Pressure bar gauge

Pressure bar gauge

Constant pressure plant

Although stall is unlikely to occur on items of plant supplied with a constant steam pressure above the condensate back pressure, any pressure in the condensate line will reduce the steam trap capacity. It is important that the steam trap is sized on the difference in the steam and condensate pressures, and not just the steam pressure, as depicted in Figure 47. With constant pressure plant, a general rule is to size the steam trap on twice the full load rating of the plant to allow for the combination of low steam pressures and high condensation rates at start-up.

1.0 bar Steam

Condensate rising to a non-pressurised sloping return line

3m 30 kW Unit heater

0.3 bar

Fig. 47 Trap capacity reduced due to an elevated return line In this example, the differential pressure across the trap is 70 % of the steam pressure. The trap is sized to pass twice the full load condition with a differential pressure of 1.0 - 0.3 bar g = 0.7 bar. Full load Steam load = 30 kW 2 x 30 kW = = 60 kW

60 kW x 3 600 = 98 kg /h 2 201 kJ / kg

Size trap to pass 98 kg/ h on a Dp of 0.7 bar.

61

Flash steam
What is flash steam and why should it be used? 'Flash Steam' is released from hot condensate when its pressure is lowered. Even water at an ordinary room temperature of 20C would boil if the pressure was lowered below 0.02 bar a, and water at 170C will boil at any pressure below 6.9 bar g. The steam released by the flashing process is just the same as the steam released when heat is added to saturated water under a constant pressure. For example, if a load is applied to a boiler, and the boiler pressure drops a little, then some of the water content of the boiler will flash-off to supplement the 'live' steam which is being produced by the supply of heat from the boiler fuel. Because it is all being produced in the boiler, all this steam is regarded as live steam. Only when flashing takes place at relatively low pressure, as at the discharge side of steam traps, is the name 'flash steam' widely used. Unfortunately, this usage has led to the erroneous conclusion that flash steam is in some way different from, and less valuable, than so called live steam . In any steam system seeking to maximise efficiency, flash steam will be separated from the condensate, where it can be utilised at low pressure, to supplement any low pressure load. Every kilogram of flash steam used in this way is a kilogram of live steam which does not need to be supplied by the boiler. It is also a kilogram conserved and not vented to atmosphere, where it would simply be lost. The reasons for the recovery of flash steam are just as compelling, both economically and environmentally as those for recovering condensate.

62

How much flash steam?

If use is to be made of flash steam, we need to know how much of it will be available. The quantity is readily determined by calculation, or it can be read from simple tables or charts. As an example, consider the jacketed vessel shown in Fig. 48. The condensate enters the trap as saturated water, at a gauge pressure of 7 bar and a temperature of 170.5C. The amount of heat in the condensate at this pressure is 721.4 kJ/kg. After passing through the steam trap, the pressure in the condensate return line is 0 bar gauge. At this pressure, the maximum amount of heat the condensate can hold is 419.0 kJ/kg and the maximum temperature is 100C. Where does the excess 302.4 kJ of heat go? In fact, it evaporates some of the condensate, but by how much? The heat needed to produce 1 kg of saturated steam from water at the same temperature at 0 bar gauge is 2 257 kJ. An amount of 302.4 kJ can therefore evaporate: 302.4 = 0.134 kg of steam 2257 from each kg of condensate, and the proportion of flash steam generated therefore equals 13.4 %.

Constant pressure steam at 7 bar g. Air vent Ball valve

Steam at 7 bar g Condensate at 7 bar g hf = 721.40 kJ/kg

Condensate at 0 bar g hf = 419.04 kJ/kg

Excess heat at 0 bar g = 721.40 - 419.04 kJ/kg = 302.4 kJ/kg

Fig. 48 Excess heat in condensate produces flash steam

63

If the equipment using steam at 7 bar g were condensing 250 kg/h, then the amount of flash steam released by the condensate at 0 bar g would be: 0.134 x 250 kg/h = 33.5 kg/h

Alternatively, as a short cut, Fig. 50 can be read directly for many of the moderate and low pressures which will be met in many plants. The previous example is shown on Fig. 49, indicating 0.134 kg of flash per kg of condensate.
Flash steam pressures
Pressure on traps bar g

13 12 11 10 9 8

Example

7 6 5 4 3 2 1 0 0 0.02 0.06 0.10 0.14 kg Flash per kg condensate 0.134 kg 0.18 0.22

Fig. 49 Quantity of flash steam Sub cooled condensate If the steam trap is of a thermostatic type which holds back condensate until it has sub-cooled below saturation temperature before discharging, then the heat in this cooler condensate will be less, and the amount of flash steam produced would be less. If the trap in the previous example discharged condensate at 15C below the steam saturation temperature, then the heat in the condensate would be less. 64

2.0

bar g bar g 1.5 bar g 1.0 bar g 0.5 bar g 0 ba r g

15 14

2.5

temp. of saturated condensate at 7 bar g = 170.5C amount of sub cooling = 15.0C temp. of sub-cooled condensate at 7 bar g = 155.5C (from steam tables) amount of heat in condensate at 155.5C = 656 kJ/kg minus heat in condensate at 0 bar g = - 419 kJ/kg Surplus = 237 kJ/kg heat in steam at 0 bar g = 2 257 kJ/kg Proportion of flash steam = 237 2 257

= 0.105 kg/kg of condensate Therefore, in this example, a reduction of condensate temperature on the upstream side of the trap by 15C has reduced the proportion of flash steam produced on the downstream side from 13.4 % to 10.5%. Pressurised condensate If the return line were connected to a vessel at a pressure of 1 bar g, then the maximum heat in the condensate at the trap discharge would be 505.6 kJ/kg and the enthalpy of evaporation at 1 bar g would be 2 201.1 kJ/kg. The proportion of the condensate which flashes off as steam at 1 bar g would then be calculated in the following way: heat in condensate at 7 bar g = 721.4 kJ/kg minus heat in condensate at 1 bar g = - 505.6 kJ/kg Surplus = 215.8 kJ/kg heat in steam at 1 bar g = 2 201.1 kJ/kg Proportion of flash steam = 215.8 2 201.1

= 0.098 kg/kg of condensate If the equipment using steam at 7 bar g were condensing 250 kg/h of steam, then the amount of flash steam released by the condensate at 1 bar g would be 0.098 x 250 = 24.5 kg/h. Therefore, the amount of flash steam produced can depend on the type of steam trap used, the steam pressure onto the trap, and the condensate pressure after the trap. 65

The flash vessel

The flash vessel separates the flash steam from the condensate in a condensate return line. Fig. 50 shows a typical flash vessel constructed to BS 5500, category 3 standard.

Flash steam OUT

Condensate IN

Condensate OUT

Fig. 50 A Typical flash vessel constructed to BS 5500, Category 3 standard When condensate and flash steam enter the vessel, condensate falls by gravity, to the base of the vessel, where it is drained back to a convenient condensate recovery system, usually a vented receiver collecting condensate ready for pumping. The flash steam in the vessel can then be piped to low pressure steam using equipment. Sizing flash steam recovery vessels In order to size the flash vessel, the following information is required: Pressure onto the steam traps supplying the vessel. The condensate flowrate. The flash steam pressure (desired or existing). Using this information, and a flash vessel sizing chart, the size of the vessel required can be determined. (Fig. 51). The following example best demonstrates flash vessel sizing, using a simple chart.

66

Example

The pressure on the steam traps is 12 bar g with a total condensate flow of 2 500 kg/h. The flash steam from the vessel is to be supplied to equipment using low pressure steam at 1 bar g. 1. From the 'Pressure on steam trap' axis at 12 bar g, move horizontally to the flash steam pressure curve at point A. 2. Drop down vertically to the condensate flowrate level, point B, and follow curved line to point C. 3. Move right from point C to meet the flash line at point D. 4. Move upwards to the flash vessel size and select the vessel. In this case, an FV8 flash vessel is required.

Method

Fig. 51 Flash vessel sizing chart

7 65 4 3 2 20
Pressure on steam traps bar g

1 Flash steam pressure bar g 0.5 0.2 0

18 16 14 12 10 8 6 4 A

Flash vessel size

FV FV FV FV 15 FV

12

18

Condensate flowrate kg/h

250 300 400 500 1000 2000 3000 4000 5000 B D C

0 0.2 0.5 1 1.5 2 3 4 5 7

10 000 15 000 20 000 30 000

Flash steam pressure bar g

6 8

10 12 14 16 18 20 %

67

Requirements for successful flash steam applications

If full use is to be made of flash steam, some basic requirements must be satisfied. It is essential to have a sufficient supply of condensate, from loads at sufficiently higher pressures, to ensure that enough flash steam is released for economic recovery. The steam traps and the equipment they are draining must be able to function satisfactorily against the back pressure applied to them by the flash system. In particular, care is needed when attempting flash steam recovery with condensate from temperature controlled equipment. At less than full loads, the steam space pressure will be lowered by the action of the control valve. If it approaches or even falls below the required flash steam pressure, recovery from this condensate requires active condensate removal. A major requirement is a suitable use for the low pressure flash steam. Ideally, it should be a low pressure load(s) which requires a supply of steam that either equals or exceeds the amount of available flash steam. Any deficit can be made up through a pressure reducing valve. If the supply of flash steam exceeds its demand, the surplus may then have to be vented to waste through a surplussing valve. It is possible to utilise the flash steam from condensate on a space heating installation - but savings will only be achieved during the heating season. When heating is not required, the recovery system becomes ineffective. Wherever possible, the best arrangement is to use flash steam from process condensate to supply process loads - and flash steam from heating condensate to supply heating loads. Supply and demand are therefore more likely to remain 'in-step'. It is also preferable to select an application for the flash steam which is reasonably close to the high pressure condensate source. Piping for low pressure steam is inevitably of a relatively large diameter. This can mean costly installation if long distances are involved

Control of flash steam pressure

The next consideration is a method of controlling the pressure of the flash steam. In some cases this pressure will find its own level and nothing more needs to be done. When supply and demand are always in-step, and particularly if the low pressure steam is used on the same equipment producing the high pressure condensate, the simplest solution is to pipe the flash steam to the low pressure plant without any other control.

68

Fig. 52 shows the application of flash steam recovery to a multi-bank air heater battery which is supplying high temperature air to a process. Condensate from the high pressure sections is flashed to low pressure, and the low pressure steam is used to preheat the cold air entering the battery. The surface area of the pre-heater section, and the relatively low temperature of the incoming air, will mean that the low pressure steam is readily condensed. Depending on operating temperatures, the flash steam will settle at a low pressure. It can even be sub-atmospheric. If site conditions and layout permit, the flash vessel and the low pressure coil trap should be located far enough below the condensate outlet to give a hydrostatic head which can push the condensate through the trap. If not, pumping traps can be used to drain both the pre-heater coil and the flash vessel. Steam condensation may mean that a vacuum breaker is required. This will prevent the pressure in the battery becoming sub-atmospheric, assisting condensate flow to the trap. Drainage from the traps is induced by gravity flow.
Temperature control valve

HP steam supply

Flash steam

Air flow

HP traps Flash vessel bypass line

LP condensate

Flash vessel

Fig. 52 Flash steam recovery on a multiple air heater battery Fig. 53 shows an application where the flash steam system is kept at a determined constant pressure by steam fed from a reducing valve. This ensures a reliable source of steam to the low pressure system if there is a lack of flash steam to meet the load. It should be remembered that this will decrease the differential pressure across the high pressure steam traps, which should be sized with this in mind. 69

Typical applications for flash steam

Flash steam supply and demand in-step This gives maximum utilisation of the available flash steam. The air heater battery discussed previously is one such system, but similar arrangements are practical with many other applications such as space heating installations using either radiant panels, or unit heaters. Figure 53 shows a system where a number of heaters are supplied with high pressure steam. The condensate from approximately 90 % of the heaters is collected and taken to a flash recovery vessel. This supplies low pressure steam to the remaining 10 % of heaters.
PRV set H P heaters HP steam supply
DP 7 1

LP Heaters

LP traps HP traps Flash vessel Flash vessel bypass line LP condensate

Fig. 53 Flash steam supply and demand in step

Trap set

With 10 % of the units supplied with steam at a lower pressure than formerly, the total heat output of the system is marginally reduced. However, it is rare to find an installation which does not have a sufficient margin of output above the normal load to accept this small reduction. Where the output of all the heaters is inadequate, it would be advantageous to install additional heater capacity so as to gain the benefit of using flash steam which otherwise would be lost. Sometimes an apparent problem arises where the use of available flash steam may require more than one heater but less than two. It would be better in this case to connect two heaters to the flash steam supply, rather than vent the excess flash steam off to waste. Two heaters together will usually pull the flash pressure down to a lower level, even to sub-atmospheric levels. To cope with this, the supply of flash steam can be supplemented through a pressure reducing valve.

70

Another example where supply and demand are in-step is the steam heated hot water storage calorifier. Some of these incorporate a secondary coil, fitted close to the bottom where the cold feedwater enters. Condensate and flash steam from the trap on the primary coil, is passed directly to the secondary coil. Here the flash steam is condensed, while giving up its heat to the feedwater. The arrangement is shown in Fig. 54. An extension of this idea is shown in Fig. 55. Here a 'packaged calorifier unit' is used with a normal steam-to-water calorifier draining through a float trap to a smaller shell-and-tube exchanger, in which the flash steam is condensed into sub-cooled condensate. The unit is fitted in series with the calorifier, to enable it to preheat the return water from the system, reducing the demand for live steam. A mechanical pump is used to lift the condensate to the return line, and the exhaust steam leaving the pump is itself condensed in the condenser. The pumping of the condensate is then achieved at virtually no energy cost. Consideration must be given to the pump filling head in that it needs to be greater than the pressure drop across the condenser tubes under full load conditions. A minimum head of 600 mm will usually achieve this.
Flow

Steam

Primary coil Secondary coil acting as a flash cooler Return Condensate

Fig. 54 Secondary flash steam coil in a storage calorifier 71

Flow to heating Steam

Heating calorifier

Temperature control Steam trap

Shell and tube flash condenser Balance line Condensate return Motive steam Return from heating

Fig. 55 Packaged calorifier and flash condenser unit

72

Flash steam supply and demand not in-step

The arrangement in Fig. 56 is an example of flash steam recovery where the supply and demand are not always in-step. Condensate from process plant releases flash steam, but the only use to be found for it is to augment the supply of steam to the space heating installation. This is quite satisfactory during the heating season, as long as the heating load exceeds the availability of flash steam. During the summer season the heating equipment will not be in use, and even during spring and autumn the heating load may not be able to use all the available flash steam. The arrangement is much less than ideal, although it is quite possible for the steam savings made during the winter to justify the cost of the flash steam recovery equipment.

Reducing valve

Surplussing valve Flash steam

Steam

Flash vessel Condensate

Fig. 56 Flash steam supply and demand not in step

73

Sometimes, surplus flash must be vented to atmosphere, and, as indicated, a surplussing valve is more suitable for this purpose than a safety valve, which usually has a 'pop' or 'on/off' action and a seat designed for infrequent operation. The surplussing valve will be set so that it begins to open slightly above the normal pressure in the system. When the heating load falls and the pressure in the system begins to increase, the pressure reducing valve supplying the make-up steam closes down. A further increase of pressure, perhaps 0.15 or 0.2 bar, is then allowed before the surplussing valve begins to open. A safety valve may still be required should the surplussing valve fail. It must be set between the surplussing valve set pressure and the system design pressure. Occasionally, during summer conditions it may be preferable to bypass the flash system with a manual valve. The condensate and its associated flash steam will then pass directly to a condensate receiver, where the flash steam will be vented to atmosphere. Boiler blowdown heat recovery applications Continuous blowdown of boiler water to control the level of TDS (total dissolved solids) within the boiler, is becoming increasingly common. It lends itself to the recovery of the heat content of the blowdown water and enables considerable savings to be made, since they continue all the time the boiler is steaming. Boiler blowdown contains massive quantities of heat which can easily be recovered as flash steam. After it passes through the blowdown control valve, the lower pressure water flows to a flash recovery vessel. There the contaminant free flash steam released is separated from the condensate, and becomes available for heating the boiler feedtank, (Fig. 57)

74

Level controller Cold water Make-up tank Condensate Hot well tank

Steam supply to injector

Flash vessel Steam Float trap Blowdown valve Boiler

Heat exchanger Feed pump

Drain

Fig. 57 Typical heat recovery from continuous blowdown

75

Spray condensing

Finally, consideration must be given to those cases where flash steam is available at low pressure, but where no suitable load is available which can make use of it. Rather than simply discharge the flash steam to waste, the arrangement in Fig. 58 can often be adopted. A lightweight but corrosion resistant chamber is fitted to the receiver tank vent. Cold water is sprayed into the chamber in sufficient quantities to just condense the flash steam. The flow of cooling water is controlled by a simple self acting temperature control, responding to the air temperature at the outlet side of the spray nozzle. It will amount to roughly 6 kg of cooling water per kg of flash steam condensed If the cooling water is of boiler feed quality, then the warmed water is added to the condensate in the receiver and re-used. This will make water savings throughout the year. Condensing water which is not of boiler feed quality, must be kept separate from the water in the receiver, as shown by the dotted lines.

Vented to atmosphere

Water in Self acting temperature control Condensate

Condensate receiver Condensed water to waste Overflow with 'U' seal

Pumped condensate

Centrifugal pump

Fig. 58 Flash steam condensing and water saving by spray 76

77

Steam tables
Specific enthalpy Pressure bar absolute 0.30 0.50 0.75 0.95 0 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 1.60 1.70 1.80 1.90 2.00 2.20 2.40 2.60 2.80 3.00 3.20 3.40 3.60 3.80 4.00 4.50 5.00 5.50 6.00 6.50 7.00 7.50 8.00 8.50 9.00 9.50 10.00 10.50 11.00 11.50 12.00 12.50 13.00 14.00 15.00 16.00 17.00 18.00 19.00 20.00 21.00 22.00 23.00 24.00 25.00 26.00 27.00 gauge 30.0 50.0 75.0 95.0 0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0 110.0 120.0 130.0 140.0 150.0 160.0 170.0 180.0 190.0 200.0 220.0 240.0 260.0 280.0 300.0 320.0 340.0 360.0 380.0 400.0 450.0 500.0 550.0 600.0 650.0 700.0 750.0 800.0 850.0 900.0 950.0 000.0 050.0 100.0 150.0 200.0 250.0 300.0 400.0 500.0 600.0 700.0 800.0 900.0 000.0 100.0 200.0 300.0 400.0 500.0 600.0 700.0 69.10 81.33 91.78 98.20 100.00 102.66 105.10 107.39 109.55 111.61 113.56 115.40 117.14 118.80 120.42 121.96 123.46 124.90 126.28 127.62 128.89 130.13 131.37 132.54 133.69 135.88 138.01 140.00 141.92 143.75 145.46 147.20 148.84 150.44 151.96 155.55 158.92 162.08 165.04 167.83 170.50 173.02 175.43 177.75 179.97 182.10 184.13 186.05 188.02 189.82 191.68 193.43 195.10 198.35 201.45 204.38 207.17 209.90 212.47 214.96 217.35 219.65 221.85 224.02 226.12 228.15 230.14 289.23 340.49 384.39 411.43 419.04 430.2 440.8 450.4 459.7 468.3 476.4 484.1 491.6 498.9 505.6 512.2 518.7 524.6 530.5 536.1 541.6 547.1 552.3 557.3 562.2 571.7 580.7 589.2 597.4 605.3 612.9 620.0 627.1 634.0 640.7 656.3 670.9 684.6 697.5 709.7 721.4 732.5 743.1 753.3 763.0 772.5 781.6 790.1 798.8 807.1 815.1 822.9 830.4 845.1 859.0 872.3 885.0 897.2 909.0 920.3 931.3 941.9 952.2 962.2 972.1 981.6 990.7 2 2 2 2 336.1 305.4 278.6 261.8 2 2 2 2 625.3 645.9 663.0 673.2 5.229 3.240 2.217 1.777 1.673 1.533 1.414 1.312 1.225 1.149 1.088 1.024 0.971 0.923 0.881 0.841 0.806 0.773 0.743 0.714 0.689 0.665 0.643 0.622 0.603 0.568 0.536 0.509 0.483 0.461 0.440 0.422 0.405 0.389 0.374 0.342 0.315 0.292 0.272 0.255 0.240 0.227 0.215 0.204 0.194 0.185 0.177 0.171 0.163 0.157 0.151 0.148 0.141 0.132 0.124 0.117 0.110 0.105 0.100 0.099 0.090 0.086 0.083 0.079 0.076 0.074 0.071 kPa Temperature C Water (h f ) kJ/kg Evaporation (h fg ) kJ/kg Steam (h g ) kJ/kg Specific volume steam m3/kg

1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2

2 257.0 2 250.2 2 243.4 2 237.2 2 231.3 2 225.6 2 220.4 2 215.4 2 210.5 2 205.6 2 201.1 2 197.0 2 192.8 2 188.7 2 184.8 2 181.0 2 177.3 2 173.7 2 170.1 2 166.7 2 163.3 2 156.9 2 150.7 2 144.7 2 139.0 2 133.4 2 128.1 2 122.9 2 117.8 2 112.9 2 108.1 2 096.7 2 086.0 2 075.7 2 066.0 2 056.8 2 047.7 2 039.2 2 030.9 2 022.9 2 015.1 2 007.5 2 000.1 1 993.0 1 986.0 1 979.1 1 972.5 1 965.4 1 959.6 1 947.1 1 935.0 1 923.4 1 912.1 1 901.3 1 890.5 1 880.2 1 870.1 1 860.1 1 850.4 1 840.9 1 831.4 1 822.2 1 813.3

2 676.0 2 680.2 2 684.2 2 687.6 2 691.0 2 693.9 2 696.8 2 699.5 2 702.1 2 704.5 2 706.7 2 709.2 2 711.5 2 713.3 2 715.3 2 717.1 2 718.9 2 720.8 2 722.4 2 724.0 2 725.5 2 728.6 2 731.4 2 733.9 2 736.4 2 738.7 2 741.0 2 742.9 2 744.9 2 746.9 2 748.8 2 753.0 2 756.9 2 760.3 2 763.5 2 766.5 2 769.1 2 771.7 2 774.0 2 776.2 2 778.1 2 780.0 2 781.7 2 783.3 2 784.8 2 786.3 2 787.6 2 788.8 2 790.0 2 792.2 2 794.0 2 795.7 2 797.1 2 798.5 2 799.5 2 800.5 2 801.4 2 802.0 2 802.6 2 803.1 2 803.5 2 803.8 2 804.0

4 6 8 2 7 8 0 4

78

Specific enthalpy Pressure bar 28.00 29.00 30.00 31.00 32.00 33.00 34.00 35.00 36.00 37.00 38.00 39.00 40.00 41.00 42.00 43.00 44.00 45.00 46.00 47.00 48.00 49.00 50.00 51.00 52.00 53.00 54.00 55.00 56.00 57.00 58.00 59.00 60.00 61.00 62.00 63.00 64.00 65.00 66.00 67.00 68.00 69.00 70.00 72.00 74.00 76.00 78.00 80.00 82.00 84.00 86.00 88.00 90.00 92.00 94.00 96.00 98.00 100.00 102.00 104.00 106.00 108.00 110.00 112.00 114.00 116.00 118.00 120.00 kPa 2 800.0 2 900.0 3 000.0 3 100.0 3 200.0 3 300.0 3 400.0 3 500.0 3 600.0 3 700.0 3 800.0 3 900.0 4 000.0 4 100.0 4 200.0 4 300.0 4 400.0 4 500.0 4 600.0 4 700.0 4 800.0 4 900.0 5 000.0 5 100.0 5 200.0 5 300.0 5 400.0 5 500.0 5 600.0 5 700.0 5 800.0 5 900.0 6 000.0 6 100.0 6 200.0 6 300.0 6 400.0 6 500.0 6 600.0 6 700.0 6 800.0 6 900.0 7 000.0 7 200.0 7 400.0 7 600.0 7 800.0 8 000.0 8 200.0 8 400.0 8 600.0 8 800.0 9 000.0 9 200.0 9 400.0 9 600.0 9 800.0 10 000.0 10 200.0 10 400.0 10 600.0 10 800.0 11 000.0 11 200.0 11 400.0 11 600.0 11 800.0 12 000.0 Temperature C 232.05 233.93 235.78 237.55 239.28 240.97 242.63 244.26 245.86 247.42 248.95 250.42 251.94 253.34 254.74 256.12 257.50 258.82 260.13 261.43 262.73 264.00 265.26 266.45 267.67 268.84 270.02 271.20 272.33 273.45 274.55 275.65 276.73 277.80 278.85 279.89 280.92 281.95 282.95 283.95 284.93 285.90 286.85 288.75 290.60 292.41 294.20 295.96 297.66 299.35 301.00 302.61 304.20 305.77 307.24 308.83 310.32 311.79 313.24 314.67 316.08 317.46 318.83 320.17 321.50 322.81 324.10 325.38 Water (h f ) kJ/kg 999.7 1 008.6 1 017.0 1 025.6 1 033.9 1 041.9 1 049.7 1 057.7 1 065.7 1 072.9 1 080.3 1 087.4 1 094.6 1 101.6 1 108.6 1 115.4 1 122.1 1 228.7 1 135.3 1 142.2 1 148.1 1 154.5 1 160.8 1 166.6 1 172.6 1 178.7 1 184.6 1 190.5 1 196.3 1 202.1 1 207.8 1 213.4 1 218.9 1 224.5 1 230.0 1 235.4 1 240.8 1 246.1 1 251.4 1 256.7 1 261.9 1 267.0 1 272.1 1 282.3 1 292.3 1 302.3 1 311.9 1 321.5 1 330.9 1 340.3 1 349.6 1 358.8 1 367.8 1 376.8 1 385.7 1 394.5 1 403.2 1 411.9 1 420.5 1 429.0 1 437.5 1 445.9 1 454.3 1 462.6 1 470.8 1 479.0 1 487.2 1 495.4 Evaporation (h fg ) kJ/kg 1 804.4 1 795.6 1 787.0 1 778.5 1 770.0 1 761.8 1 753.8 1 745.5 1 737.2 1 729.5 1 721.6 1 714.1 1 706.3 1 698.3 1 691.2 1 683.7 1 676.2 1 668.9 1 666.6 1 654.4 1 647.1 1 639.9 1 632.8 1 626.9 1 619.0 1 612.0 1 605.1 1 598.2 1 591.3 1 584.5 1 577.7 1 571.0 1 564.4 1 557.6 1 550.9 1 544.3 1 537.3 1 531.2 1 524.7 1 518.1 1 511.6 1 501.1 1 498.7 1 485.8 1 473.0 1 460.2 1 447.6 1 435.0 1 422.5 1 410.0 1 397.6 1 385.2 1 372.7 1 360.3 1 348.0 1 335.7 1 323.3 1 310.9 1 298.7 1 286.3 1 274.0 1 261.7 1 249.3 1 237.0 1 224.6 1 212.2 1 199.8 1 187.3 Steam (h g ) kJ/kg 2 804.1 2 804.2 2 804.1 2 804.1 2 803.9 2 803.7 2 805.5 2 803.2 2 802.9 2 802.4 2 801.9 2 801.5 2 800.9 2 799.9 2 799.8 2 799.1 2 798.3 2 797.6 2 796.9 2 796.6 2 795.2 2 794.4 2 793.6 2 792.6 2 791.6 2 790.7 2 789.7 2 788.7 2 787.6 2 786.6 2 785.5 2 784.4 2 783.3 2 782.1 2 780.9 2 779.7 2 778.5 2 777.3 2 776.1 2 774.8 2 773.5 2 772.1 2 770.8 2 768.1 2 765.3 2 762.5 2 759.5 2 756.5 2 753.4 2 750.3 2 747.2 2 744.0 2 740.5 2 737.1 2 733.7 2 730.2 2 726.5 2 722.8 2 719.2 2 715.3 2 711.5 2 707.6 2 703.6 2 699.6 2 695.4 2 691.2 2 687.0 2 682.7

Specific volume steam m3/kg 0.068 9 0.066 6 0.064 5 0.062 5 0.060 5 0.058 7 0.057 1 0.055 4 0.053 9 0.052 4 0.051 0 0.049 8 0.048 5 0.047 3 0.046 1 0.045 1 0.044 1 0.043 1 0.042 1 0.041 2 0.040 3 0.039 4 0.038 6 0.037 8 0.037 1 0.036 4 0.035 7 0.035 0 0.034 3 0.033 7 0.033 1 0.032 5 0.031 9 0.031 4 0.030 8 0.030 3 0.029 8 0.029 3 0.028 8 0.028 3 0.027 8 0.027 4 0.027 0 0.026 2 0.025 4 0.024 6 0.023 9 0.023 3 0.022 6 0.022 0 0.021 4 0.020 8 0.020 2 0.019 7 0.019 2 0.018 7 0.018 3 0.017 8 0.017 4 0.017 0 0.016 6 0.016 2 0.015 8 0.015 4 0.015 0 0.014 7 0.014 4 0.014 1

79

Further information
This technical reference guide has been designed to give works engineers or energy managers, an introduction into the subject of condensate and flash steam recovery. It is quite impossible to cover all aspects of this subject, as almost every installation is unique. We have tried to cover most alternatives exist, but it may be that we have omitted some options. Advice is always freely available from our team of regional engineers, or by telephone or letter from head office as required.

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Appendix 1 Condensate line sizing chart

100,000 50,000

500

400

350

300

250

200
150 100 80

20,000 10,000 5,000

Condensate rate kg/h

65 50 40
Condensate line size mm

32

2,000 1,000 500

25 20 15 10

200 100 50

20 10

Steam system pressure bar g

50 30 20 15 10 5 2 1 0.5 0

250
Steam temperature C

30 20 10 5 4 3 2 1 0.5 0

Condensate system pressure bar g

200 180 160 140 120 100

81

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Spirax-Sarco Limited, Charlton House, Cheltenham, Gloucestershire, GL53 8ER UK. Tel: +44 (0)1242 521361 Fax: +44 (0)1242 573342 E-mail: enq@spiraxuk.attmail.com Internet: www.spirax-sarco.com
Copyright 1999 Spirax Sarco is a registered trademark of Spirax-Sarco Limited

TR-GCM-05

CM Issue 1