Condensate Return Systems Spirax Sarco Inc.

Presented by Greyling Carey

Typical Steam Circuit

KETTLES

SPACE HEATING TANKS

Feed Tank Boiler Feed Pump

Steam and Condensate Striving for maximum efficiency

Steam generation, distribution and utilization
Boiler

Process

Condensate removal, heat recovery and return

Why Return Condensate?

Condensate is an extremely valuable resource. Its high heat content justifies returning it to the feedwater system. Condensate has already been treated and thus water treatment costs are lowered. The high cost of condensate disposal is avoided. Water charges are lowered because fresh water is not continually being added to the boiler.

Condensate Recovery Savings of up to 25%

Driving Forces

CUSTOMER

Energy Costs

Profitability

Safety

Productivity Environment

Reliability

www.SpiraxSarco.com

Energy Costs The Cost of Steam

Gas prices exceed $4.00 per million Btu's in February 2012 August 2003 average price is $9.80 $/MMBTU gas average steam cost = $16.96/1000 lbs. of steam Boiler efficiency 85% (Stack Losses) Boiler Blowdown 6%
Water/Chemical Costs - $0.80/1000 lbs. Condensate Recovery 90% of steam load

National Average Steam Cost = $9.70/1000 lbs. of steam

Condensate Recovery Payback Analysis

Instructions: Input data in white boxes where appropriate: Do NOT input data in blue boxes: Data Condensate Load Annual Hours of Operation Raw Water Cost Sewage or Effluent Cost Water Treatment Chemicals Condensate Return Temperature Make Up Water Temperature Steam Cost Boiler Operating Pressure 5000 8760 2 1 2 190 60 5.00 150 1196 339 Boiler Blowdown Cost of Fuel Boiler Efficiency Additional Information Maximum Temperature permitted in sewer Is water being used to cool condensate Savings Energy savings in condensate Make up Water & Treatment Chemical Savings Sewage/Effluent Cost Savings Raw Water (cooling) Cost Savings Boiler Blowdown Savings CO2 Emissions Reduction TOTAL ANNUAL SAVINGS 28,470 21,007 5,252 0 490 386 55,219 $/year $/year $/year $/year $/year Tons/year $/year 140 No Deg. F Yes or No 5 4.10 85% lbs/hr Hours per year $ per 1000 galls $ per 1000 galls $ per 1000 galls Deg. F Deg. F $ per 1000 lbs psig hg (BTU/lb) hf (BTU/lb) % $ per million BTU %

Typical Condensate Observations

Condensate Recovery saves:
Water costs Preheating energy costs Chemical treatment costs Effluent costs Boiler Blowdown % Emissions Damage to infrastructure Safety incidents

(Just 10 gpm can save over $50,000 per year)

Typical Issues Caused with Improper Condensate Systems

System Reliability Safety Operation Control Productivity Product Quality Economic Environmental

Problems Incurred From Stalled Condensate Systems

Waterhammer Control Corrosion Erosion Equipment damage Personnel Safety Maintenance costs

What happens when a Condensate System Stalls

The Heat Transfer Equipment & Piping Infrastructure Damages: (HX, AHU, Kettles, Cylinders, Autoclaves, Sterilizers & etc.) Banging Knocking Corroding Leaking Fouling Annoying

When the System Stall We Do What?

Condensate is now :
Being dumped to the pad or drain Wasted ($$$$$$) Arousing EPA interest Causing safety concerns Annoying noises or flash vapor

The Problems Begin?

Engineering & Design Architect Drawings Contractors Installation System Being Expanded Operation of the System Maintenance PMs

Condensate Drainage
What if condensate cannot drain? Condensate backs up Results in:
Cooling Output swings Waterhammer O2 & CO2 corrosion Thermal stresses Fouling

Solutions
Drain the Condensate to the Sewer Eliminate the Backpressure

Suffer in Silence?

Effective Condensate Drainage and Return Systems

Three Types of Condensate Return Systems

Gravity Drain Vented open system 0 pressure gravity drain to the boiler house
Differential Pressure Condensate thats being pushed back to the boiler house by steam trap differential pressure Closed or Vented System Being pumped by electrical or mechanical pumps

Condensation & Steam Flow

Specific volume of steam - 3.89 ft/lb. at 100psig

Specific volume of steam - 26.8 ft/lb at Patm Specific volume of condensate - 0.017 ft/lb. 1600 times smaller Creates steam flow from high to low pressure Vacuum potential

Line Sizing
How do we size condensate lines? Differential Pressure?

Lbs/hr or liquid flow gpm?

Velocity? Copy similar installation?

To Size a Condensate Line

1. Determine Condensate Load lbs/hr 2. Two Phase lbs/hr or Liquid GPM 3. Determine the Total Back-Pressures (return line pressure, lift & frictional losses) 4. Calculate % Flash Steam at Flow Rate than Size Condensate Line based on Flash Steam 5. Differential Pressure Available 6. Base Sizing on Velocity at load lbs/hr or GPM (two phase maximum of 4,000 ft/min) (liquid maximum of 360 ft/min)

Back Pressure In Condensate Return Systems

Pressure at end of Main: DA tank +Vertical Lift +Frictional Resistance in Piping

Back Pressure

Quantity of Flash Steam in Line

100 lb. Flash Steam 99.44% of Total Volume

900 lb. Condensate

0.56 % of Total Volume

5,000 lbs/hr Steam/Condensate Load

STEAM LINE (maximum 6,000 ft/min)
100 psig steam line 3 50 psig steam line 4 15 psig steam line 6

CONDENSATE LINE (maximum of 4,000 ft/min) two-phase

100 psig to 10 psig 10.6% flash = 530 lb/hr requires a 3 line 100 psig to 5 psig 11.8% flash = 590 lb/r requires a 4 line 100 psig to 0 psig 13.3% flash = 665 lb/hr requires 5 line

Sizing of Condensate Return Lines Quantity of Flash Steam

1000 lb/h

Mass

Volume Condensate 0.017ft3/h Flash Steam 26.8 ft3/h

60 PSIG

Condensate 900lb/h Flash Steam 100lb/h

0 PSIG

Whats Flash Steam?

Steam created when hot condensate is exposed to a lower pressure.

FLASH STEAM

FLASH STEAM occurs when hot condensate at high pressure is released to a lower pressure. At the lower pressure, the heat content (SENSIBLE HEAT) of the water (hot condensate) cannot exist in that form. A portion of the water boils off and becomes FLASH STEAM Flash Steam contains valuable BTUs / lb. Of heat which can be utilized for lower pressure applications.

Condensate Line, Flash Tank, and Vent Line Sizing

Ways to Move Condensate Back to the Boiler Room

Gravity Drain Strictly Pushing with Pressure Electric Centrifugal Pumps Mechanical Pumps Pump Traps (dedicated to one piece of steam equipment)

Condensate Pumps
When the air handling unit is at full capacity, the steam pressure will be at 10 psig or 240 F the condensate will flash

Condensate Pumping

Condensate Load (lb./h)

Electric Pump Capacity (GPM)

or Pressure Powered Pump Capacity (lb./h)

Electric Centrifugal Pumps

Simplex Duplex With NPSH

Electric Condensate Pumps

Flash Steam from Vent

2- Phase flow: Condensate & Flash Steam at 212 F

HOT Condensate

Cavitation
Cavitation causes:
Vibration Mechanical seals to overheat and fail Pitting of the impeller Motor bearing failure Capacity reduction Condensate losses High operating & maintenance costs

Mechanical Pumps

Simplex Duplex Triplex Quadplex

Pressure Powered Pump

Pump Trap

Both Float Trap and Mechanical Pump all in One Body Dedicated to one piece of equipment Can work under pressure to Full Vacuum Total Fully Closed Condensate System

The Automatic Pump Trap - for smaller applications

Filling

Exhaust open
Condensate IN OUT First stage trap seat open

Stalling

Exhaust open
Condensate IN

2nd stage trap seat open

Outlet check valve closed - NO flow

High Level Trip

Steam valve open Condensate pumped OUT Check valve open

Pumping

Steam in
Float dropping

Condensate pumped out

Exhausting
Steam inlet CLOSED Exhaust OPEN

Condensate

Filling AGAIN

Exhaust open
Condensate IN OUT First stage trap seat open

Steam at 240 F

Typical Run of Condensate Line?

Revised Installation Layout

Vacuum Breaker

Steam at 15 psig

66 F
At 0 psig, with a 12 head, we can guarantee psi dP
12

P = 0 psig
12
12 12

Air Handling Unit needs to be at least 5 FEET above floor level

24

Condensate Line Connections

Condensate

Condensate

Condensate

Incorrect

Correct

Why We Return Condensate

To Optimize Steam Systems and Energy Dollars?

$$$$$$$

Questions?