Boiler Condensate Return Basics. Presented by Steve Connor February 24, 2016

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1 Boiler Condensate Return Basics Presented by Steve Connor February 24, 2016

2 What We Are Covering Today? Brief review of the total steam system Why a proper condensate return system is so important Condensate return and affect on the property s operation What compromises the optimum condensate return system The corrective actions Delivering condensate back to the boiler room The choices for holding and treating this condensate. Summary Q/A 2

3 Supply and Return System(s) 150 psig 366 F HP Steam Strainer LP Steam PRV 15 psig 250 F T Trap T Trap Motive Force T Trap T Trap H P Cond Return Vent T Trap LP Condensate Return Boiler DA D A Tank Tank Feed Pump Cond Recovery & Pump Legend Steam Condensate 3 3

4 Total Boiler Room Feed system Chemical feed Water softener To drain To drain 4 Water inlet

5 Supply and Return System(s) 150 psig 366 F HP Steam Strainer LP Steam PRV 15 psig 250 F T Trap T Trap Motive Force T Trap T Trap H P Cond Return Vent T Trap LP Condensate Return Boiler DA D A Tank Tank Feed Pump Cond Recovery & Pump Legend Steam Condensate 5 5

6 Reasons why condensate system is important Operating cost reduction Reliability Safety

7 Let s first look at Efficiency & Cost of Operation OK

8 2011 Steam Rate ($15.00/1,000 lb) What is the cost of steam?

9 Steam - Basic Concepts Boiler operating at 100 psig and 200 O F feed water Sensible Heat Latent Heat of Fusion Sensible Heat Latent Heat of Vaporization (or Latent Heat of Condensation) 1 lb steam at 338 O F F F F F F. 0 0 F. Btu per pound of water lb water at 338 O F 1 lb water at 200 O F

10 Saturated Steam Table 32 deg. F Pressure (psig) Saturation Temp Volume (ft 3 /lb) Sensible Heat (btu/lb) Latent Heat (btu/lb) Total Heat (btu/lb)

11 FWT 30 Gauge Pressure - psig Capacity At Operating Pressures vs. FWT.

12 Energy Dollars at Risk $ DOWN THE DRAIN Every 10 degree drop in feed water temperature equals a 1% drop in efficiency! 12

13 Blowdown Heat Recovery Types Blowdown Heat Recovery Unit Proportional blowdown heat recovery system Atmospheric feed or deaerator Automatically controls TDS Single or Multiple Boilers Blowdown is cooled before discharge (Code compliance) 13

14 Condensate Recovery Savings Derived from: Fuel savings Chemicals Water Sewer costs Bringing back condensate at higher pressures will result in even greater savings!

15 Reliability Issues

16 Split System Pressure Regulating Valve Jacketed Kettle Plate & Frame Shell & Tube 16

17 Condensate Back-up or Stall 17

18 Constant Orifice Purge

19 Steam power pump Steam Pump Trap

20 Vacuum breaker Vacuum breaker Water leg Trap NOTE: 2.3 feet of static head = 1 pound pressure

21 Air vent

22 Non Condensable Gas Corrosion Almost 2 times more corrosive at 122 o F than at 86 o F Dissolved oxygen is 10 times more corrosive than CO 2 50 F 86 F 122 F O2 CO2 Courtesy:

23 Air and Corrosion The Piping is Subject to Corrosion ( CO 2 + H 2 O H 2 CO 3 ) Subcooled Condensate + CO 2 Forms Carbonic Acid 40% more corrosive when combined with dissolved O2!! 23 23

24 Carbonic Acid Corrosion Cause and Effect CO 2 + H 2 O = H 2 CO 3 Created where condensate is not fully drained. Attacks pipe and coil material.

25 Carbonic Acid attack Cause and Effect CO 2 + H 2 O = H 2 CO

26 Most Economical Long-Term Approach Mechanical Chemical 26

27 Steam/Water Separator Separation Mechanism Cyclonic (centrifugal force) Baffle (directional flow change) Coalescence (trapping media) pad) Cyclonic Type 27

28 Secondary Steam Branch Line In-line separator To condensate return line 28

29 Drip pockets & Steam Trap Set Isolation valves Check valve strainer trap

30 Drip Pockets 6-10 Drip Leg BD and Venting Locations: Low Spots End of Main Ahead of Expansion Joints Ahead of Valves, Bends & Regulators Steam Trap Locate every feet in a linear length of steam pipe 30

31 Suggested Sizing Steam Main Size Drip Leg Diameter Drip leg Length

32 Moving condensate from source to boiler room Motive force of steam pressure differential

33 Standard models 200 F or less 210 F floor mounted units w/ low NPSH pumps 212 F elevated units available, thereby increasing NPSH Condensate Transfer Tanks

34 Steam & Condensate Velocity Boiler operating pressure Pounds of condensate Pressure at trap inlet Pressure in line Condensate pipe diameter Allowable pressure drop Typical Velocities in steam systems: Process Piping (70 90 MPH) LP Heating Systems (45 70 MPH) fpm fpm Typical Velocities in Condensate return systems Liquid fpm Bi-phase Approx fpm Note: Pressure drop should not exceed 20% of boiler s maximum operating pressure

35 Supply and Return System(s) 150 psig 366 F HP Steam Strainer LP Steam T Trap T Trap Motive Force Boiler T Trap T Trap DA D A Tank Tank T Common Condensate Return Feed Pump Trap Legend Steam Condensate

36 Saturated Steam Table 32 deg. F Pressure (psig) Saturation Temp Volume (ft 3 /lb) Sensible Heat (btu/lb) Latent Heat (btu/lb) Total Heat (btu/lb)

37 Steam & Condensate Velocity Typical Velocities in steam systems: Process Piping fpm (70 90 MPH) LP Heating Systems fpm (45 70 MPH) Preferred Velocities in Condensate return systems Liquid Bi-phase fpm Approx fpm

38 Condensate Pipe sizing Example: 2000#/HR 7000 ft/min ¼# drop 150# inlet Zero & 15# outlet Condensate pipe sizing criteria Boiler operating pressure Pounds of condensate Pressure at trap inlet Pressure in line Condensate pipe diameter Allowable pressure drop

39 And what s the Safety Issue with condensate? Efficiency Reliability Capture Transportation

40 Cause & Effect of Water Hammer Three Types of Water Hammer: Hydraulic Thermal Differential

41 Thermal water hammer Thermal The steam condensing void is rapidly filled with water

42 Thermal Imaging & diffusion of condensate lines Diffuser

43 Flash Tank Flash Tank Higher temperature drip traps Vent to atmosphere Use flash steam for LP use (non-modulating) Preheat boiler feed water Steam User Drip trap location 43

44 Calculating Flash Steam % Formula: (hf1 hf2 )/hfg2 = % Flash HF1: Sensible Btu s in HF2: Sensible Btu s out HFG2: Latent Btu s out Example: User operating at 150 psig with 15 psig = 120/946 = 13% Flash Captured!. Btu s SAVED!. Water & Sewer charges SAVED!. Chemicals SAVED! 44

45 HP Condensate Recovery 175 psig 366 F HP Steam Strainer LP Steam PRV 15 psig 250 F T Trap T Trap Motive Force T Trap T Trap H P Condensate Return T Trap Feed Tank or DA D A Tank Boiler Feed Pump Cond. Pump

46 High Pressure Condensate Receiver Takes high pressure condensate directly from the user. No need to deaerate. Pump directly into boiler Feed the HPR from the DA

47 Holding the boiler s feed water and protecting the system

48 HOT Condensate returned Boiler Feed System Deaerator Steam diffusing tube A vented receiver, wastes energy. Pressurized receiver, saves energy. 48

49 Chemical Feed Tank Mixing and Dispensing Phosphonates Chelant (de-scaler) Polymers Sulfite Non-sulfite scavengers Amines (neutralizing or filming) 49

50 Final Summary The boiler is part of a total system including its piping supply and return network, and all the associated accessories supporting the total whole. Proper condensate line engineering impacts energy efficiency, production reliability, and safety Every 10 degree pickup in feedwater temperature = 1% fuel savings Condensate is sensible energy which increases with increasing operating pressures Reliability is affected by system backup (Stall) and system corrosion Condensate line water hammer is normally Thermal type Flash recovery systems can mitigate problem and save energy Recommended velocities in bi-phase condensate lines is ft/min As line pressure in bi-phase condensate increases the volume decreases, reducing line size for same velocity. Condensate line sizing involves knowing boiler pressure, trap inlet pressure, pounds of condensate, common line pressure, desired velocity, and desired pressure drop 50

51 Steve Connor Training & Technical Consultant 51

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