understand how a good heating system design on paper can
TRANSCRIPT
Positive Condensate Drainage from Heat Transfer Equipment under Modulating Steam Conditions
Understand how a good heating system design on paper can become a big problem once installed
November 13 2017 CNY Expo -
Looked Good on Paperhellip
Types of Heat Transfer
DirectThe heating medium is directly mixed (convection) with the
substance being heated ie ldquoDirect injectionrdquo
Indirect(Heat Exchange Equipment)
Heat energy from the heating medium is passed to the substance being heated through a physical barrier (conduction)
Steam Heat Transfer 101
1 Steam Supply 2 Heat Transfer 3 Condensate Removal
Heat Exchanger Flow
Heat Exchanger Sizing
Q = U x A x ∆T where U = K (dx Fouling Factors)
dX A
Type amp Thickness of Materials of Construction
Copper
Copper
Stainless Steel
Double Wall
Standard HX sizes163- 258- 352- 446- 540- 634- 729- 823- 917-SQFT
Example 887760 = 324 x 274 x 100
Application requires 274 SQFT but the closest suitable size is 352 SQFT
Therefore the HX starts over-sized by 285
Normal Operation
Heat Exchanger
P2
P1
Product Temperature Input
P1 gt P2 = Heat Exchanger Dry
Vacuum = Negative Differential Pressure
Steam occupies 1675 times the amount of space than water
When steam condenses in a ldquoClosed-Systemrdquo a vacuum is created
3 ft
3 ft
3 ft
Conventional Condensate Removal
System Pressure Modulating vs Constant
Pre
ssu
reP
ress
ure
Time
Time
Modulating Steam Traps
Inverted Bucketbull Continuous Steam ndash Goodbull Intermittent (OnOff) Steam ndash Poorbull Economical Choice Metal-on-Metal
Float amp Thermostaticbull Continuous Steam ndash Excellentbull Intermittent (OnOff) Steam ndash Excellentbull Optimum Choice for Process
Valve Head amp Seat
Float Mechanism
Air Vent
Downstream Lift = System Back Pressure
Heat Exchanger
Stall Condition ndash No Steam Supply
P2
Product Temperature Input
P1ltP2=Heat Exchanger Flooded
P1
Stall Chart
StallPump Mode
Trap Mode
65 = Stallof Load Point
What does a stall chart not take into consideration
Domestic Hot Water
15 PSIG Steam Supply 250F
40F to 140F 100 GPM
0 PSIG Back-Pressure 212F
(aka Gravity-Drain)
After HX is selectedhellipnow the real world
For real-world conditions
Q = U x A x ∆T where U = K (dx)
Domestic WaterFlow Rate Varies with demand typically low to no flow in evening hours
Building HeatFlow rate varies with VFDs responding to demand
Less flow requires less flow of heat (Q)
Domestic WaterIncoming water temperature rises in summer months
Building HeatOutside Air Temperature rises is summer months
Both reduce ∆T requiring less flow of heat
Saturated Steam Table
Actual Stall Conditions40F to 140F 100 GPM using 15 PSIG Steam Supply
Heat Load Summary - Calculating Stall
Flow Rate (GPM)
Heat Load(BTUhr)
Steam Tempin HX
(F)
Steam Pressurein HX(PSIG)
Latent Heat of Steam(BTUs)
Steam amp Condensate Flow
(lbshr)
Trap Differential
(ΔP)
System Condition
100 5004000 2455 1287 9486 5275 1287 Trap Mode
95 4753800 2377 927 9538 4984 927 Trap Mode
85 4253400 2222 325 9638 4413 325 Trap Mode
75 3753000 2066 -149 9737 3854 -149 Stall - Pump Mode
65 3252600 1911 -512 9832 3308 -512 Stall - Pump Mode
50 2502000 1678 -899 9974 2509 -899 Stall - Pump Mode
25 1251000 1289 -1253 10203 1226 -1253 Stall - Pump Mode
15 750600 1133 -1329 10297 729 -1329 Stall - Pump Mode
10 500400 1056 -1357 10337 484 -1357 Stall - Pump Mode
5 250200 978 -1381 10381 241 -1381 Stall - Pump Mode
Reasons for System Stall
bull Overly conservative fouling factors during HEX design ndash adds additional surface area
bull Back pressure at equipment discharge ndash elevation or static pressure
bull Modulating Control ndash Steam pressure
bull Vacuum
bull Process demands- Flow or temp changes
bull Oversized equipment ndash excess surface area
Effects of System Stall
bull Inadequate condensate drainage
bull Water hammer (Thermal Shock)
bull Frozen coils damaged tube bundles
bull Poor temperature control
bull Control valve hunting ndash control stability
bull Reduction in heat transfer capacity
Pumping Condensate
bull Whatrsquos unique about condensatebull High temperature fluid
bull Constant phase change or flashing
bull Intermittent supply inconsistent suction head
2 Types of Condensate Pumps1 Electric Pumps
2 Pressure-Powered Pumps
Electric Pump Operation
What does a lower pressure due to the boiling pointLowers saturation pointGenerates flash steamFlash steam causes cavitation
Vent = Energy Loss
What is Flash Steam
Flash Capacity Calculation
Return amp Vent Sizing
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Looked Good on Paperhellip
Types of Heat Transfer
DirectThe heating medium is directly mixed (convection) with the
substance being heated ie ldquoDirect injectionrdquo
Indirect(Heat Exchange Equipment)
Heat energy from the heating medium is passed to the substance being heated through a physical barrier (conduction)
Steam Heat Transfer 101
1 Steam Supply 2 Heat Transfer 3 Condensate Removal
Heat Exchanger Flow
Heat Exchanger Sizing
Q = U x A x ∆T where U = K (dx Fouling Factors)
dX A
Type amp Thickness of Materials of Construction
Copper
Copper
Stainless Steel
Double Wall
Standard HX sizes163- 258- 352- 446- 540- 634- 729- 823- 917-SQFT
Example 887760 = 324 x 274 x 100
Application requires 274 SQFT but the closest suitable size is 352 SQFT
Therefore the HX starts over-sized by 285
Normal Operation
Heat Exchanger
P2
P1
Product Temperature Input
P1 gt P2 = Heat Exchanger Dry
Vacuum = Negative Differential Pressure
Steam occupies 1675 times the amount of space than water
When steam condenses in a ldquoClosed-Systemrdquo a vacuum is created
3 ft
3 ft
3 ft
Conventional Condensate Removal
System Pressure Modulating vs Constant
Pre
ssu
reP
ress
ure
Time
Time
Modulating Steam Traps
Inverted Bucketbull Continuous Steam ndash Goodbull Intermittent (OnOff) Steam ndash Poorbull Economical Choice Metal-on-Metal
Float amp Thermostaticbull Continuous Steam ndash Excellentbull Intermittent (OnOff) Steam ndash Excellentbull Optimum Choice for Process
Valve Head amp Seat
Float Mechanism
Air Vent
Downstream Lift = System Back Pressure
Heat Exchanger
Stall Condition ndash No Steam Supply
P2
Product Temperature Input
P1ltP2=Heat Exchanger Flooded
P1
Stall Chart
StallPump Mode
Trap Mode
65 = Stallof Load Point
What does a stall chart not take into consideration
Domestic Hot Water
15 PSIG Steam Supply 250F
40F to 140F 100 GPM
0 PSIG Back-Pressure 212F
(aka Gravity-Drain)
After HX is selectedhellipnow the real world
For real-world conditions
Q = U x A x ∆T where U = K (dx)
Domestic WaterFlow Rate Varies with demand typically low to no flow in evening hours
Building HeatFlow rate varies with VFDs responding to demand
Less flow requires less flow of heat (Q)
Domestic WaterIncoming water temperature rises in summer months
Building HeatOutside Air Temperature rises is summer months
Both reduce ∆T requiring less flow of heat
Saturated Steam Table
Actual Stall Conditions40F to 140F 100 GPM using 15 PSIG Steam Supply
Heat Load Summary - Calculating Stall
Flow Rate (GPM)
Heat Load(BTUhr)
Steam Tempin HX
(F)
Steam Pressurein HX(PSIG)
Latent Heat of Steam(BTUs)
Steam amp Condensate Flow
(lbshr)
Trap Differential
(ΔP)
System Condition
100 5004000 2455 1287 9486 5275 1287 Trap Mode
95 4753800 2377 927 9538 4984 927 Trap Mode
85 4253400 2222 325 9638 4413 325 Trap Mode
75 3753000 2066 -149 9737 3854 -149 Stall - Pump Mode
65 3252600 1911 -512 9832 3308 -512 Stall - Pump Mode
50 2502000 1678 -899 9974 2509 -899 Stall - Pump Mode
25 1251000 1289 -1253 10203 1226 -1253 Stall - Pump Mode
15 750600 1133 -1329 10297 729 -1329 Stall - Pump Mode
10 500400 1056 -1357 10337 484 -1357 Stall - Pump Mode
5 250200 978 -1381 10381 241 -1381 Stall - Pump Mode
Reasons for System Stall
bull Overly conservative fouling factors during HEX design ndash adds additional surface area
bull Back pressure at equipment discharge ndash elevation or static pressure
bull Modulating Control ndash Steam pressure
bull Vacuum
bull Process demands- Flow or temp changes
bull Oversized equipment ndash excess surface area
Effects of System Stall
bull Inadequate condensate drainage
bull Water hammer (Thermal Shock)
bull Frozen coils damaged tube bundles
bull Poor temperature control
bull Control valve hunting ndash control stability
bull Reduction in heat transfer capacity
Pumping Condensate
bull Whatrsquos unique about condensatebull High temperature fluid
bull Constant phase change or flashing
bull Intermittent supply inconsistent suction head
2 Types of Condensate Pumps1 Electric Pumps
2 Pressure-Powered Pumps
Electric Pump Operation
What does a lower pressure due to the boiling pointLowers saturation pointGenerates flash steamFlash steam causes cavitation
Vent = Energy Loss
What is Flash Steam
Flash Capacity Calculation
Return amp Vent Sizing
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Types of Heat Transfer
DirectThe heating medium is directly mixed (convection) with the
substance being heated ie ldquoDirect injectionrdquo
Indirect(Heat Exchange Equipment)
Heat energy from the heating medium is passed to the substance being heated through a physical barrier (conduction)
Steam Heat Transfer 101
1 Steam Supply 2 Heat Transfer 3 Condensate Removal
Heat Exchanger Flow
Heat Exchanger Sizing
Q = U x A x ∆T where U = K (dx Fouling Factors)
dX A
Type amp Thickness of Materials of Construction
Copper
Copper
Stainless Steel
Double Wall
Standard HX sizes163- 258- 352- 446- 540- 634- 729- 823- 917-SQFT
Example 887760 = 324 x 274 x 100
Application requires 274 SQFT but the closest suitable size is 352 SQFT
Therefore the HX starts over-sized by 285
Normal Operation
Heat Exchanger
P2
P1
Product Temperature Input
P1 gt P2 = Heat Exchanger Dry
Vacuum = Negative Differential Pressure
Steam occupies 1675 times the amount of space than water
When steam condenses in a ldquoClosed-Systemrdquo a vacuum is created
3 ft
3 ft
3 ft
Conventional Condensate Removal
System Pressure Modulating vs Constant
Pre
ssu
reP
ress
ure
Time
Time
Modulating Steam Traps
Inverted Bucketbull Continuous Steam ndash Goodbull Intermittent (OnOff) Steam ndash Poorbull Economical Choice Metal-on-Metal
Float amp Thermostaticbull Continuous Steam ndash Excellentbull Intermittent (OnOff) Steam ndash Excellentbull Optimum Choice for Process
Valve Head amp Seat
Float Mechanism
Air Vent
Downstream Lift = System Back Pressure
Heat Exchanger
Stall Condition ndash No Steam Supply
P2
Product Temperature Input
P1ltP2=Heat Exchanger Flooded
P1
Stall Chart
StallPump Mode
Trap Mode
65 = Stallof Load Point
What does a stall chart not take into consideration
Domestic Hot Water
15 PSIG Steam Supply 250F
40F to 140F 100 GPM
0 PSIG Back-Pressure 212F
(aka Gravity-Drain)
After HX is selectedhellipnow the real world
For real-world conditions
Q = U x A x ∆T where U = K (dx)
Domestic WaterFlow Rate Varies with demand typically low to no flow in evening hours
Building HeatFlow rate varies with VFDs responding to demand
Less flow requires less flow of heat (Q)
Domestic WaterIncoming water temperature rises in summer months
Building HeatOutside Air Temperature rises is summer months
Both reduce ∆T requiring less flow of heat
Saturated Steam Table
Actual Stall Conditions40F to 140F 100 GPM using 15 PSIG Steam Supply
Heat Load Summary - Calculating Stall
Flow Rate (GPM)
Heat Load(BTUhr)
Steam Tempin HX
(F)
Steam Pressurein HX(PSIG)
Latent Heat of Steam(BTUs)
Steam amp Condensate Flow
(lbshr)
Trap Differential
(ΔP)
System Condition
100 5004000 2455 1287 9486 5275 1287 Trap Mode
95 4753800 2377 927 9538 4984 927 Trap Mode
85 4253400 2222 325 9638 4413 325 Trap Mode
75 3753000 2066 -149 9737 3854 -149 Stall - Pump Mode
65 3252600 1911 -512 9832 3308 -512 Stall - Pump Mode
50 2502000 1678 -899 9974 2509 -899 Stall - Pump Mode
25 1251000 1289 -1253 10203 1226 -1253 Stall - Pump Mode
15 750600 1133 -1329 10297 729 -1329 Stall - Pump Mode
10 500400 1056 -1357 10337 484 -1357 Stall - Pump Mode
5 250200 978 -1381 10381 241 -1381 Stall - Pump Mode
Reasons for System Stall
bull Overly conservative fouling factors during HEX design ndash adds additional surface area
bull Back pressure at equipment discharge ndash elevation or static pressure
bull Modulating Control ndash Steam pressure
bull Vacuum
bull Process demands- Flow or temp changes
bull Oversized equipment ndash excess surface area
Effects of System Stall
bull Inadequate condensate drainage
bull Water hammer (Thermal Shock)
bull Frozen coils damaged tube bundles
bull Poor temperature control
bull Control valve hunting ndash control stability
bull Reduction in heat transfer capacity
Pumping Condensate
bull Whatrsquos unique about condensatebull High temperature fluid
bull Constant phase change or flashing
bull Intermittent supply inconsistent suction head
2 Types of Condensate Pumps1 Electric Pumps
2 Pressure-Powered Pumps
Electric Pump Operation
What does a lower pressure due to the boiling pointLowers saturation pointGenerates flash steamFlash steam causes cavitation
Vent = Energy Loss
What is Flash Steam
Flash Capacity Calculation
Return amp Vent Sizing
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Steam Heat Transfer 101
1 Steam Supply 2 Heat Transfer 3 Condensate Removal
Heat Exchanger Flow
Heat Exchanger Sizing
Q = U x A x ∆T where U = K (dx Fouling Factors)
dX A
Type amp Thickness of Materials of Construction
Copper
Copper
Stainless Steel
Double Wall
Standard HX sizes163- 258- 352- 446- 540- 634- 729- 823- 917-SQFT
Example 887760 = 324 x 274 x 100
Application requires 274 SQFT but the closest suitable size is 352 SQFT
Therefore the HX starts over-sized by 285
Normal Operation
Heat Exchanger
P2
P1
Product Temperature Input
P1 gt P2 = Heat Exchanger Dry
Vacuum = Negative Differential Pressure
Steam occupies 1675 times the amount of space than water
When steam condenses in a ldquoClosed-Systemrdquo a vacuum is created
3 ft
3 ft
3 ft
Conventional Condensate Removal
System Pressure Modulating vs Constant
Pre
ssu
reP
ress
ure
Time
Time
Modulating Steam Traps
Inverted Bucketbull Continuous Steam ndash Goodbull Intermittent (OnOff) Steam ndash Poorbull Economical Choice Metal-on-Metal
Float amp Thermostaticbull Continuous Steam ndash Excellentbull Intermittent (OnOff) Steam ndash Excellentbull Optimum Choice for Process
Valve Head amp Seat
Float Mechanism
Air Vent
Downstream Lift = System Back Pressure
Heat Exchanger
Stall Condition ndash No Steam Supply
P2
Product Temperature Input
P1ltP2=Heat Exchanger Flooded
P1
Stall Chart
StallPump Mode
Trap Mode
65 = Stallof Load Point
What does a stall chart not take into consideration
Domestic Hot Water
15 PSIG Steam Supply 250F
40F to 140F 100 GPM
0 PSIG Back-Pressure 212F
(aka Gravity-Drain)
After HX is selectedhellipnow the real world
For real-world conditions
Q = U x A x ∆T where U = K (dx)
Domestic WaterFlow Rate Varies with demand typically low to no flow in evening hours
Building HeatFlow rate varies with VFDs responding to demand
Less flow requires less flow of heat (Q)
Domestic WaterIncoming water temperature rises in summer months
Building HeatOutside Air Temperature rises is summer months
Both reduce ∆T requiring less flow of heat
Saturated Steam Table
Actual Stall Conditions40F to 140F 100 GPM using 15 PSIG Steam Supply
Heat Load Summary - Calculating Stall
Flow Rate (GPM)
Heat Load(BTUhr)
Steam Tempin HX
(F)
Steam Pressurein HX(PSIG)
Latent Heat of Steam(BTUs)
Steam amp Condensate Flow
(lbshr)
Trap Differential
(ΔP)
System Condition
100 5004000 2455 1287 9486 5275 1287 Trap Mode
95 4753800 2377 927 9538 4984 927 Trap Mode
85 4253400 2222 325 9638 4413 325 Trap Mode
75 3753000 2066 -149 9737 3854 -149 Stall - Pump Mode
65 3252600 1911 -512 9832 3308 -512 Stall - Pump Mode
50 2502000 1678 -899 9974 2509 -899 Stall - Pump Mode
25 1251000 1289 -1253 10203 1226 -1253 Stall - Pump Mode
15 750600 1133 -1329 10297 729 -1329 Stall - Pump Mode
10 500400 1056 -1357 10337 484 -1357 Stall - Pump Mode
5 250200 978 -1381 10381 241 -1381 Stall - Pump Mode
Reasons for System Stall
bull Overly conservative fouling factors during HEX design ndash adds additional surface area
bull Back pressure at equipment discharge ndash elevation or static pressure
bull Modulating Control ndash Steam pressure
bull Vacuum
bull Process demands- Flow or temp changes
bull Oversized equipment ndash excess surface area
Effects of System Stall
bull Inadequate condensate drainage
bull Water hammer (Thermal Shock)
bull Frozen coils damaged tube bundles
bull Poor temperature control
bull Control valve hunting ndash control stability
bull Reduction in heat transfer capacity
Pumping Condensate
bull Whatrsquos unique about condensatebull High temperature fluid
bull Constant phase change or flashing
bull Intermittent supply inconsistent suction head
2 Types of Condensate Pumps1 Electric Pumps
2 Pressure-Powered Pumps
Electric Pump Operation
What does a lower pressure due to the boiling pointLowers saturation pointGenerates flash steamFlash steam causes cavitation
Vent = Energy Loss
What is Flash Steam
Flash Capacity Calculation
Return amp Vent Sizing
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Heat Exchanger Flow
Heat Exchanger Sizing
Q = U x A x ∆T where U = K (dx Fouling Factors)
dX A
Type amp Thickness of Materials of Construction
Copper
Copper
Stainless Steel
Double Wall
Standard HX sizes163- 258- 352- 446- 540- 634- 729- 823- 917-SQFT
Example 887760 = 324 x 274 x 100
Application requires 274 SQFT but the closest suitable size is 352 SQFT
Therefore the HX starts over-sized by 285
Normal Operation
Heat Exchanger
P2
P1
Product Temperature Input
P1 gt P2 = Heat Exchanger Dry
Vacuum = Negative Differential Pressure
Steam occupies 1675 times the amount of space than water
When steam condenses in a ldquoClosed-Systemrdquo a vacuum is created
3 ft
3 ft
3 ft
Conventional Condensate Removal
System Pressure Modulating vs Constant
Pre
ssu
reP
ress
ure
Time
Time
Modulating Steam Traps
Inverted Bucketbull Continuous Steam ndash Goodbull Intermittent (OnOff) Steam ndash Poorbull Economical Choice Metal-on-Metal
Float amp Thermostaticbull Continuous Steam ndash Excellentbull Intermittent (OnOff) Steam ndash Excellentbull Optimum Choice for Process
Valve Head amp Seat
Float Mechanism
Air Vent
Downstream Lift = System Back Pressure
Heat Exchanger
Stall Condition ndash No Steam Supply
P2
Product Temperature Input
P1ltP2=Heat Exchanger Flooded
P1
Stall Chart
StallPump Mode
Trap Mode
65 = Stallof Load Point
What does a stall chart not take into consideration
Domestic Hot Water
15 PSIG Steam Supply 250F
40F to 140F 100 GPM
0 PSIG Back-Pressure 212F
(aka Gravity-Drain)
After HX is selectedhellipnow the real world
For real-world conditions
Q = U x A x ∆T where U = K (dx)
Domestic WaterFlow Rate Varies with demand typically low to no flow in evening hours
Building HeatFlow rate varies with VFDs responding to demand
Less flow requires less flow of heat (Q)
Domestic WaterIncoming water temperature rises in summer months
Building HeatOutside Air Temperature rises is summer months
Both reduce ∆T requiring less flow of heat
Saturated Steam Table
Actual Stall Conditions40F to 140F 100 GPM using 15 PSIG Steam Supply
Heat Load Summary - Calculating Stall
Flow Rate (GPM)
Heat Load(BTUhr)
Steam Tempin HX
(F)
Steam Pressurein HX(PSIG)
Latent Heat of Steam(BTUs)
Steam amp Condensate Flow
(lbshr)
Trap Differential
(ΔP)
System Condition
100 5004000 2455 1287 9486 5275 1287 Trap Mode
95 4753800 2377 927 9538 4984 927 Trap Mode
85 4253400 2222 325 9638 4413 325 Trap Mode
75 3753000 2066 -149 9737 3854 -149 Stall - Pump Mode
65 3252600 1911 -512 9832 3308 -512 Stall - Pump Mode
50 2502000 1678 -899 9974 2509 -899 Stall - Pump Mode
25 1251000 1289 -1253 10203 1226 -1253 Stall - Pump Mode
15 750600 1133 -1329 10297 729 -1329 Stall - Pump Mode
10 500400 1056 -1357 10337 484 -1357 Stall - Pump Mode
5 250200 978 -1381 10381 241 -1381 Stall - Pump Mode
Reasons for System Stall
bull Overly conservative fouling factors during HEX design ndash adds additional surface area
bull Back pressure at equipment discharge ndash elevation or static pressure
bull Modulating Control ndash Steam pressure
bull Vacuum
bull Process demands- Flow or temp changes
bull Oversized equipment ndash excess surface area
Effects of System Stall
bull Inadequate condensate drainage
bull Water hammer (Thermal Shock)
bull Frozen coils damaged tube bundles
bull Poor temperature control
bull Control valve hunting ndash control stability
bull Reduction in heat transfer capacity
Pumping Condensate
bull Whatrsquos unique about condensatebull High temperature fluid
bull Constant phase change or flashing
bull Intermittent supply inconsistent suction head
2 Types of Condensate Pumps1 Electric Pumps
2 Pressure-Powered Pumps
Electric Pump Operation
What does a lower pressure due to the boiling pointLowers saturation pointGenerates flash steamFlash steam causes cavitation
Vent = Energy Loss
What is Flash Steam
Flash Capacity Calculation
Return amp Vent Sizing
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Heat Exchanger Sizing
Q = U x A x ∆T where U = K (dx Fouling Factors)
dX A
Type amp Thickness of Materials of Construction
Copper
Copper
Stainless Steel
Double Wall
Standard HX sizes163- 258- 352- 446- 540- 634- 729- 823- 917-SQFT
Example 887760 = 324 x 274 x 100
Application requires 274 SQFT but the closest suitable size is 352 SQFT
Therefore the HX starts over-sized by 285
Normal Operation
Heat Exchanger
P2
P1
Product Temperature Input
P1 gt P2 = Heat Exchanger Dry
Vacuum = Negative Differential Pressure
Steam occupies 1675 times the amount of space than water
When steam condenses in a ldquoClosed-Systemrdquo a vacuum is created
3 ft
3 ft
3 ft
Conventional Condensate Removal
System Pressure Modulating vs Constant
Pre
ssu
reP
ress
ure
Time
Time
Modulating Steam Traps
Inverted Bucketbull Continuous Steam ndash Goodbull Intermittent (OnOff) Steam ndash Poorbull Economical Choice Metal-on-Metal
Float amp Thermostaticbull Continuous Steam ndash Excellentbull Intermittent (OnOff) Steam ndash Excellentbull Optimum Choice for Process
Valve Head amp Seat
Float Mechanism
Air Vent
Downstream Lift = System Back Pressure
Heat Exchanger
Stall Condition ndash No Steam Supply
P2
Product Temperature Input
P1ltP2=Heat Exchanger Flooded
P1
Stall Chart
StallPump Mode
Trap Mode
65 = Stallof Load Point
What does a stall chart not take into consideration
Domestic Hot Water
15 PSIG Steam Supply 250F
40F to 140F 100 GPM
0 PSIG Back-Pressure 212F
(aka Gravity-Drain)
After HX is selectedhellipnow the real world
For real-world conditions
Q = U x A x ∆T where U = K (dx)
Domestic WaterFlow Rate Varies with demand typically low to no flow in evening hours
Building HeatFlow rate varies with VFDs responding to demand
Less flow requires less flow of heat (Q)
Domestic WaterIncoming water temperature rises in summer months
Building HeatOutside Air Temperature rises is summer months
Both reduce ∆T requiring less flow of heat
Saturated Steam Table
Actual Stall Conditions40F to 140F 100 GPM using 15 PSIG Steam Supply
Heat Load Summary - Calculating Stall
Flow Rate (GPM)
Heat Load(BTUhr)
Steam Tempin HX
(F)
Steam Pressurein HX(PSIG)
Latent Heat of Steam(BTUs)
Steam amp Condensate Flow
(lbshr)
Trap Differential
(ΔP)
System Condition
100 5004000 2455 1287 9486 5275 1287 Trap Mode
95 4753800 2377 927 9538 4984 927 Trap Mode
85 4253400 2222 325 9638 4413 325 Trap Mode
75 3753000 2066 -149 9737 3854 -149 Stall - Pump Mode
65 3252600 1911 -512 9832 3308 -512 Stall - Pump Mode
50 2502000 1678 -899 9974 2509 -899 Stall - Pump Mode
25 1251000 1289 -1253 10203 1226 -1253 Stall - Pump Mode
15 750600 1133 -1329 10297 729 -1329 Stall - Pump Mode
10 500400 1056 -1357 10337 484 -1357 Stall - Pump Mode
5 250200 978 -1381 10381 241 -1381 Stall - Pump Mode
Reasons for System Stall
bull Overly conservative fouling factors during HEX design ndash adds additional surface area
bull Back pressure at equipment discharge ndash elevation or static pressure
bull Modulating Control ndash Steam pressure
bull Vacuum
bull Process demands- Flow or temp changes
bull Oversized equipment ndash excess surface area
Effects of System Stall
bull Inadequate condensate drainage
bull Water hammer (Thermal Shock)
bull Frozen coils damaged tube bundles
bull Poor temperature control
bull Control valve hunting ndash control stability
bull Reduction in heat transfer capacity
Pumping Condensate
bull Whatrsquos unique about condensatebull High temperature fluid
bull Constant phase change or flashing
bull Intermittent supply inconsistent suction head
2 Types of Condensate Pumps1 Electric Pumps
2 Pressure-Powered Pumps
Electric Pump Operation
What does a lower pressure due to the boiling pointLowers saturation pointGenerates flash steamFlash steam causes cavitation
Vent = Energy Loss
What is Flash Steam
Flash Capacity Calculation
Return amp Vent Sizing
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Normal Operation
Heat Exchanger
P2
P1
Product Temperature Input
P1 gt P2 = Heat Exchanger Dry
Vacuum = Negative Differential Pressure
Steam occupies 1675 times the amount of space than water
When steam condenses in a ldquoClosed-Systemrdquo a vacuum is created
3 ft
3 ft
3 ft
Conventional Condensate Removal
System Pressure Modulating vs Constant
Pre
ssu
reP
ress
ure
Time
Time
Modulating Steam Traps
Inverted Bucketbull Continuous Steam ndash Goodbull Intermittent (OnOff) Steam ndash Poorbull Economical Choice Metal-on-Metal
Float amp Thermostaticbull Continuous Steam ndash Excellentbull Intermittent (OnOff) Steam ndash Excellentbull Optimum Choice for Process
Valve Head amp Seat
Float Mechanism
Air Vent
Downstream Lift = System Back Pressure
Heat Exchanger
Stall Condition ndash No Steam Supply
P2
Product Temperature Input
P1ltP2=Heat Exchanger Flooded
P1
Stall Chart
StallPump Mode
Trap Mode
65 = Stallof Load Point
What does a stall chart not take into consideration
Domestic Hot Water
15 PSIG Steam Supply 250F
40F to 140F 100 GPM
0 PSIG Back-Pressure 212F
(aka Gravity-Drain)
After HX is selectedhellipnow the real world
For real-world conditions
Q = U x A x ∆T where U = K (dx)
Domestic WaterFlow Rate Varies with demand typically low to no flow in evening hours
Building HeatFlow rate varies with VFDs responding to demand
Less flow requires less flow of heat (Q)
Domestic WaterIncoming water temperature rises in summer months
Building HeatOutside Air Temperature rises is summer months
Both reduce ∆T requiring less flow of heat
Saturated Steam Table
Actual Stall Conditions40F to 140F 100 GPM using 15 PSIG Steam Supply
Heat Load Summary - Calculating Stall
Flow Rate (GPM)
Heat Load(BTUhr)
Steam Tempin HX
(F)
Steam Pressurein HX(PSIG)
Latent Heat of Steam(BTUs)
Steam amp Condensate Flow
(lbshr)
Trap Differential
(ΔP)
System Condition
100 5004000 2455 1287 9486 5275 1287 Trap Mode
95 4753800 2377 927 9538 4984 927 Trap Mode
85 4253400 2222 325 9638 4413 325 Trap Mode
75 3753000 2066 -149 9737 3854 -149 Stall - Pump Mode
65 3252600 1911 -512 9832 3308 -512 Stall - Pump Mode
50 2502000 1678 -899 9974 2509 -899 Stall - Pump Mode
25 1251000 1289 -1253 10203 1226 -1253 Stall - Pump Mode
15 750600 1133 -1329 10297 729 -1329 Stall - Pump Mode
10 500400 1056 -1357 10337 484 -1357 Stall - Pump Mode
5 250200 978 -1381 10381 241 -1381 Stall - Pump Mode
Reasons for System Stall
bull Overly conservative fouling factors during HEX design ndash adds additional surface area
bull Back pressure at equipment discharge ndash elevation or static pressure
bull Modulating Control ndash Steam pressure
bull Vacuum
bull Process demands- Flow or temp changes
bull Oversized equipment ndash excess surface area
Effects of System Stall
bull Inadequate condensate drainage
bull Water hammer (Thermal Shock)
bull Frozen coils damaged tube bundles
bull Poor temperature control
bull Control valve hunting ndash control stability
bull Reduction in heat transfer capacity
Pumping Condensate
bull Whatrsquos unique about condensatebull High temperature fluid
bull Constant phase change or flashing
bull Intermittent supply inconsistent suction head
2 Types of Condensate Pumps1 Electric Pumps
2 Pressure-Powered Pumps
Electric Pump Operation
What does a lower pressure due to the boiling pointLowers saturation pointGenerates flash steamFlash steam causes cavitation
Vent = Energy Loss
What is Flash Steam
Flash Capacity Calculation
Return amp Vent Sizing
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Vacuum = Negative Differential Pressure
Steam occupies 1675 times the amount of space than water
When steam condenses in a ldquoClosed-Systemrdquo a vacuum is created
3 ft
3 ft
3 ft
Conventional Condensate Removal
System Pressure Modulating vs Constant
Pre
ssu
reP
ress
ure
Time
Time
Modulating Steam Traps
Inverted Bucketbull Continuous Steam ndash Goodbull Intermittent (OnOff) Steam ndash Poorbull Economical Choice Metal-on-Metal
Float amp Thermostaticbull Continuous Steam ndash Excellentbull Intermittent (OnOff) Steam ndash Excellentbull Optimum Choice for Process
Valve Head amp Seat
Float Mechanism
Air Vent
Downstream Lift = System Back Pressure
Heat Exchanger
Stall Condition ndash No Steam Supply
P2
Product Temperature Input
P1ltP2=Heat Exchanger Flooded
P1
Stall Chart
StallPump Mode
Trap Mode
65 = Stallof Load Point
What does a stall chart not take into consideration
Domestic Hot Water
15 PSIG Steam Supply 250F
40F to 140F 100 GPM
0 PSIG Back-Pressure 212F
(aka Gravity-Drain)
After HX is selectedhellipnow the real world
For real-world conditions
Q = U x A x ∆T where U = K (dx)
Domestic WaterFlow Rate Varies with demand typically low to no flow in evening hours
Building HeatFlow rate varies with VFDs responding to demand
Less flow requires less flow of heat (Q)
Domestic WaterIncoming water temperature rises in summer months
Building HeatOutside Air Temperature rises is summer months
Both reduce ∆T requiring less flow of heat
Saturated Steam Table
Actual Stall Conditions40F to 140F 100 GPM using 15 PSIG Steam Supply
Heat Load Summary - Calculating Stall
Flow Rate (GPM)
Heat Load(BTUhr)
Steam Tempin HX
(F)
Steam Pressurein HX(PSIG)
Latent Heat of Steam(BTUs)
Steam amp Condensate Flow
(lbshr)
Trap Differential
(ΔP)
System Condition
100 5004000 2455 1287 9486 5275 1287 Trap Mode
95 4753800 2377 927 9538 4984 927 Trap Mode
85 4253400 2222 325 9638 4413 325 Trap Mode
75 3753000 2066 -149 9737 3854 -149 Stall - Pump Mode
65 3252600 1911 -512 9832 3308 -512 Stall - Pump Mode
50 2502000 1678 -899 9974 2509 -899 Stall - Pump Mode
25 1251000 1289 -1253 10203 1226 -1253 Stall - Pump Mode
15 750600 1133 -1329 10297 729 -1329 Stall - Pump Mode
10 500400 1056 -1357 10337 484 -1357 Stall - Pump Mode
5 250200 978 -1381 10381 241 -1381 Stall - Pump Mode
Reasons for System Stall
bull Overly conservative fouling factors during HEX design ndash adds additional surface area
bull Back pressure at equipment discharge ndash elevation or static pressure
bull Modulating Control ndash Steam pressure
bull Vacuum
bull Process demands- Flow or temp changes
bull Oversized equipment ndash excess surface area
Effects of System Stall
bull Inadequate condensate drainage
bull Water hammer (Thermal Shock)
bull Frozen coils damaged tube bundles
bull Poor temperature control
bull Control valve hunting ndash control stability
bull Reduction in heat transfer capacity
Pumping Condensate
bull Whatrsquos unique about condensatebull High temperature fluid
bull Constant phase change or flashing
bull Intermittent supply inconsistent suction head
2 Types of Condensate Pumps1 Electric Pumps
2 Pressure-Powered Pumps
Electric Pump Operation
What does a lower pressure due to the boiling pointLowers saturation pointGenerates flash steamFlash steam causes cavitation
Vent = Energy Loss
What is Flash Steam
Flash Capacity Calculation
Return amp Vent Sizing
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Conventional Condensate Removal
System Pressure Modulating vs Constant
Pre
ssu
reP
ress
ure
Time
Time
Modulating Steam Traps
Inverted Bucketbull Continuous Steam ndash Goodbull Intermittent (OnOff) Steam ndash Poorbull Economical Choice Metal-on-Metal
Float amp Thermostaticbull Continuous Steam ndash Excellentbull Intermittent (OnOff) Steam ndash Excellentbull Optimum Choice for Process
Valve Head amp Seat
Float Mechanism
Air Vent
Downstream Lift = System Back Pressure
Heat Exchanger
Stall Condition ndash No Steam Supply
P2
Product Temperature Input
P1ltP2=Heat Exchanger Flooded
P1
Stall Chart
StallPump Mode
Trap Mode
65 = Stallof Load Point
What does a stall chart not take into consideration
Domestic Hot Water
15 PSIG Steam Supply 250F
40F to 140F 100 GPM
0 PSIG Back-Pressure 212F
(aka Gravity-Drain)
After HX is selectedhellipnow the real world
For real-world conditions
Q = U x A x ∆T where U = K (dx)
Domestic WaterFlow Rate Varies with demand typically low to no flow in evening hours
Building HeatFlow rate varies with VFDs responding to demand
Less flow requires less flow of heat (Q)
Domestic WaterIncoming water temperature rises in summer months
Building HeatOutside Air Temperature rises is summer months
Both reduce ∆T requiring less flow of heat
Saturated Steam Table
Actual Stall Conditions40F to 140F 100 GPM using 15 PSIG Steam Supply
Heat Load Summary - Calculating Stall
Flow Rate (GPM)
Heat Load(BTUhr)
Steam Tempin HX
(F)
Steam Pressurein HX(PSIG)
Latent Heat of Steam(BTUs)
Steam amp Condensate Flow
(lbshr)
Trap Differential
(ΔP)
System Condition
100 5004000 2455 1287 9486 5275 1287 Trap Mode
95 4753800 2377 927 9538 4984 927 Trap Mode
85 4253400 2222 325 9638 4413 325 Trap Mode
75 3753000 2066 -149 9737 3854 -149 Stall - Pump Mode
65 3252600 1911 -512 9832 3308 -512 Stall - Pump Mode
50 2502000 1678 -899 9974 2509 -899 Stall - Pump Mode
25 1251000 1289 -1253 10203 1226 -1253 Stall - Pump Mode
15 750600 1133 -1329 10297 729 -1329 Stall - Pump Mode
10 500400 1056 -1357 10337 484 -1357 Stall - Pump Mode
5 250200 978 -1381 10381 241 -1381 Stall - Pump Mode
Reasons for System Stall
bull Overly conservative fouling factors during HEX design ndash adds additional surface area
bull Back pressure at equipment discharge ndash elevation or static pressure
bull Modulating Control ndash Steam pressure
bull Vacuum
bull Process demands- Flow or temp changes
bull Oversized equipment ndash excess surface area
Effects of System Stall
bull Inadequate condensate drainage
bull Water hammer (Thermal Shock)
bull Frozen coils damaged tube bundles
bull Poor temperature control
bull Control valve hunting ndash control stability
bull Reduction in heat transfer capacity
Pumping Condensate
bull Whatrsquos unique about condensatebull High temperature fluid
bull Constant phase change or flashing
bull Intermittent supply inconsistent suction head
2 Types of Condensate Pumps1 Electric Pumps
2 Pressure-Powered Pumps
Electric Pump Operation
What does a lower pressure due to the boiling pointLowers saturation pointGenerates flash steamFlash steam causes cavitation
Vent = Energy Loss
What is Flash Steam
Flash Capacity Calculation
Return amp Vent Sizing
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
System Pressure Modulating vs Constant
Pre
ssu
reP
ress
ure
Time
Time
Modulating Steam Traps
Inverted Bucketbull Continuous Steam ndash Goodbull Intermittent (OnOff) Steam ndash Poorbull Economical Choice Metal-on-Metal
Float amp Thermostaticbull Continuous Steam ndash Excellentbull Intermittent (OnOff) Steam ndash Excellentbull Optimum Choice for Process
Valve Head amp Seat
Float Mechanism
Air Vent
Downstream Lift = System Back Pressure
Heat Exchanger
Stall Condition ndash No Steam Supply
P2
Product Temperature Input
P1ltP2=Heat Exchanger Flooded
P1
Stall Chart
StallPump Mode
Trap Mode
65 = Stallof Load Point
What does a stall chart not take into consideration
Domestic Hot Water
15 PSIG Steam Supply 250F
40F to 140F 100 GPM
0 PSIG Back-Pressure 212F
(aka Gravity-Drain)
After HX is selectedhellipnow the real world
For real-world conditions
Q = U x A x ∆T where U = K (dx)
Domestic WaterFlow Rate Varies with demand typically low to no flow in evening hours
Building HeatFlow rate varies with VFDs responding to demand
Less flow requires less flow of heat (Q)
Domestic WaterIncoming water temperature rises in summer months
Building HeatOutside Air Temperature rises is summer months
Both reduce ∆T requiring less flow of heat
Saturated Steam Table
Actual Stall Conditions40F to 140F 100 GPM using 15 PSIG Steam Supply
Heat Load Summary - Calculating Stall
Flow Rate (GPM)
Heat Load(BTUhr)
Steam Tempin HX
(F)
Steam Pressurein HX(PSIG)
Latent Heat of Steam(BTUs)
Steam amp Condensate Flow
(lbshr)
Trap Differential
(ΔP)
System Condition
100 5004000 2455 1287 9486 5275 1287 Trap Mode
95 4753800 2377 927 9538 4984 927 Trap Mode
85 4253400 2222 325 9638 4413 325 Trap Mode
75 3753000 2066 -149 9737 3854 -149 Stall - Pump Mode
65 3252600 1911 -512 9832 3308 -512 Stall - Pump Mode
50 2502000 1678 -899 9974 2509 -899 Stall - Pump Mode
25 1251000 1289 -1253 10203 1226 -1253 Stall - Pump Mode
15 750600 1133 -1329 10297 729 -1329 Stall - Pump Mode
10 500400 1056 -1357 10337 484 -1357 Stall - Pump Mode
5 250200 978 -1381 10381 241 -1381 Stall - Pump Mode
Reasons for System Stall
bull Overly conservative fouling factors during HEX design ndash adds additional surface area
bull Back pressure at equipment discharge ndash elevation or static pressure
bull Modulating Control ndash Steam pressure
bull Vacuum
bull Process demands- Flow or temp changes
bull Oversized equipment ndash excess surface area
Effects of System Stall
bull Inadequate condensate drainage
bull Water hammer (Thermal Shock)
bull Frozen coils damaged tube bundles
bull Poor temperature control
bull Control valve hunting ndash control stability
bull Reduction in heat transfer capacity
Pumping Condensate
bull Whatrsquos unique about condensatebull High temperature fluid
bull Constant phase change or flashing
bull Intermittent supply inconsistent suction head
2 Types of Condensate Pumps1 Electric Pumps
2 Pressure-Powered Pumps
Electric Pump Operation
What does a lower pressure due to the boiling pointLowers saturation pointGenerates flash steamFlash steam causes cavitation
Vent = Energy Loss
What is Flash Steam
Flash Capacity Calculation
Return amp Vent Sizing
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Modulating Steam Traps
Inverted Bucketbull Continuous Steam ndash Goodbull Intermittent (OnOff) Steam ndash Poorbull Economical Choice Metal-on-Metal
Float amp Thermostaticbull Continuous Steam ndash Excellentbull Intermittent (OnOff) Steam ndash Excellentbull Optimum Choice for Process
Valve Head amp Seat
Float Mechanism
Air Vent
Downstream Lift = System Back Pressure
Heat Exchanger
Stall Condition ndash No Steam Supply
P2
Product Temperature Input
P1ltP2=Heat Exchanger Flooded
P1
Stall Chart
StallPump Mode
Trap Mode
65 = Stallof Load Point
What does a stall chart not take into consideration
Domestic Hot Water
15 PSIG Steam Supply 250F
40F to 140F 100 GPM
0 PSIG Back-Pressure 212F
(aka Gravity-Drain)
After HX is selectedhellipnow the real world
For real-world conditions
Q = U x A x ∆T where U = K (dx)
Domestic WaterFlow Rate Varies with demand typically low to no flow in evening hours
Building HeatFlow rate varies with VFDs responding to demand
Less flow requires less flow of heat (Q)
Domestic WaterIncoming water temperature rises in summer months
Building HeatOutside Air Temperature rises is summer months
Both reduce ∆T requiring less flow of heat
Saturated Steam Table
Actual Stall Conditions40F to 140F 100 GPM using 15 PSIG Steam Supply
Heat Load Summary - Calculating Stall
Flow Rate (GPM)
Heat Load(BTUhr)
Steam Tempin HX
(F)
Steam Pressurein HX(PSIG)
Latent Heat of Steam(BTUs)
Steam amp Condensate Flow
(lbshr)
Trap Differential
(ΔP)
System Condition
100 5004000 2455 1287 9486 5275 1287 Trap Mode
95 4753800 2377 927 9538 4984 927 Trap Mode
85 4253400 2222 325 9638 4413 325 Trap Mode
75 3753000 2066 -149 9737 3854 -149 Stall - Pump Mode
65 3252600 1911 -512 9832 3308 -512 Stall - Pump Mode
50 2502000 1678 -899 9974 2509 -899 Stall - Pump Mode
25 1251000 1289 -1253 10203 1226 -1253 Stall - Pump Mode
15 750600 1133 -1329 10297 729 -1329 Stall - Pump Mode
10 500400 1056 -1357 10337 484 -1357 Stall - Pump Mode
5 250200 978 -1381 10381 241 -1381 Stall - Pump Mode
Reasons for System Stall
bull Overly conservative fouling factors during HEX design ndash adds additional surface area
bull Back pressure at equipment discharge ndash elevation or static pressure
bull Modulating Control ndash Steam pressure
bull Vacuum
bull Process demands- Flow or temp changes
bull Oversized equipment ndash excess surface area
Effects of System Stall
bull Inadequate condensate drainage
bull Water hammer (Thermal Shock)
bull Frozen coils damaged tube bundles
bull Poor temperature control
bull Control valve hunting ndash control stability
bull Reduction in heat transfer capacity
Pumping Condensate
bull Whatrsquos unique about condensatebull High temperature fluid
bull Constant phase change or flashing
bull Intermittent supply inconsistent suction head
2 Types of Condensate Pumps1 Electric Pumps
2 Pressure-Powered Pumps
Electric Pump Operation
What does a lower pressure due to the boiling pointLowers saturation pointGenerates flash steamFlash steam causes cavitation
Vent = Energy Loss
What is Flash Steam
Flash Capacity Calculation
Return amp Vent Sizing
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Downstream Lift = System Back Pressure
Heat Exchanger
Stall Condition ndash No Steam Supply
P2
Product Temperature Input
P1ltP2=Heat Exchanger Flooded
P1
Stall Chart
StallPump Mode
Trap Mode
65 = Stallof Load Point
What does a stall chart not take into consideration
Domestic Hot Water
15 PSIG Steam Supply 250F
40F to 140F 100 GPM
0 PSIG Back-Pressure 212F
(aka Gravity-Drain)
After HX is selectedhellipnow the real world
For real-world conditions
Q = U x A x ∆T where U = K (dx)
Domestic WaterFlow Rate Varies with demand typically low to no flow in evening hours
Building HeatFlow rate varies with VFDs responding to demand
Less flow requires less flow of heat (Q)
Domestic WaterIncoming water temperature rises in summer months
Building HeatOutside Air Temperature rises is summer months
Both reduce ∆T requiring less flow of heat
Saturated Steam Table
Actual Stall Conditions40F to 140F 100 GPM using 15 PSIG Steam Supply
Heat Load Summary - Calculating Stall
Flow Rate (GPM)
Heat Load(BTUhr)
Steam Tempin HX
(F)
Steam Pressurein HX(PSIG)
Latent Heat of Steam(BTUs)
Steam amp Condensate Flow
(lbshr)
Trap Differential
(ΔP)
System Condition
100 5004000 2455 1287 9486 5275 1287 Trap Mode
95 4753800 2377 927 9538 4984 927 Trap Mode
85 4253400 2222 325 9638 4413 325 Trap Mode
75 3753000 2066 -149 9737 3854 -149 Stall - Pump Mode
65 3252600 1911 -512 9832 3308 -512 Stall - Pump Mode
50 2502000 1678 -899 9974 2509 -899 Stall - Pump Mode
25 1251000 1289 -1253 10203 1226 -1253 Stall - Pump Mode
15 750600 1133 -1329 10297 729 -1329 Stall - Pump Mode
10 500400 1056 -1357 10337 484 -1357 Stall - Pump Mode
5 250200 978 -1381 10381 241 -1381 Stall - Pump Mode
Reasons for System Stall
bull Overly conservative fouling factors during HEX design ndash adds additional surface area
bull Back pressure at equipment discharge ndash elevation or static pressure
bull Modulating Control ndash Steam pressure
bull Vacuum
bull Process demands- Flow or temp changes
bull Oversized equipment ndash excess surface area
Effects of System Stall
bull Inadequate condensate drainage
bull Water hammer (Thermal Shock)
bull Frozen coils damaged tube bundles
bull Poor temperature control
bull Control valve hunting ndash control stability
bull Reduction in heat transfer capacity
Pumping Condensate
bull Whatrsquos unique about condensatebull High temperature fluid
bull Constant phase change or flashing
bull Intermittent supply inconsistent suction head
2 Types of Condensate Pumps1 Electric Pumps
2 Pressure-Powered Pumps
Electric Pump Operation
What does a lower pressure due to the boiling pointLowers saturation pointGenerates flash steamFlash steam causes cavitation
Vent = Energy Loss
What is Flash Steam
Flash Capacity Calculation
Return amp Vent Sizing
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Heat Exchanger
Stall Condition ndash No Steam Supply
P2
Product Temperature Input
P1ltP2=Heat Exchanger Flooded
P1
Stall Chart
StallPump Mode
Trap Mode
65 = Stallof Load Point
What does a stall chart not take into consideration
Domestic Hot Water
15 PSIG Steam Supply 250F
40F to 140F 100 GPM
0 PSIG Back-Pressure 212F
(aka Gravity-Drain)
After HX is selectedhellipnow the real world
For real-world conditions
Q = U x A x ∆T where U = K (dx)
Domestic WaterFlow Rate Varies with demand typically low to no flow in evening hours
Building HeatFlow rate varies with VFDs responding to demand
Less flow requires less flow of heat (Q)
Domestic WaterIncoming water temperature rises in summer months
Building HeatOutside Air Temperature rises is summer months
Both reduce ∆T requiring less flow of heat
Saturated Steam Table
Actual Stall Conditions40F to 140F 100 GPM using 15 PSIG Steam Supply
Heat Load Summary - Calculating Stall
Flow Rate (GPM)
Heat Load(BTUhr)
Steam Tempin HX
(F)
Steam Pressurein HX(PSIG)
Latent Heat of Steam(BTUs)
Steam amp Condensate Flow
(lbshr)
Trap Differential
(ΔP)
System Condition
100 5004000 2455 1287 9486 5275 1287 Trap Mode
95 4753800 2377 927 9538 4984 927 Trap Mode
85 4253400 2222 325 9638 4413 325 Trap Mode
75 3753000 2066 -149 9737 3854 -149 Stall - Pump Mode
65 3252600 1911 -512 9832 3308 -512 Stall - Pump Mode
50 2502000 1678 -899 9974 2509 -899 Stall - Pump Mode
25 1251000 1289 -1253 10203 1226 -1253 Stall - Pump Mode
15 750600 1133 -1329 10297 729 -1329 Stall - Pump Mode
10 500400 1056 -1357 10337 484 -1357 Stall - Pump Mode
5 250200 978 -1381 10381 241 -1381 Stall - Pump Mode
Reasons for System Stall
bull Overly conservative fouling factors during HEX design ndash adds additional surface area
bull Back pressure at equipment discharge ndash elevation or static pressure
bull Modulating Control ndash Steam pressure
bull Vacuum
bull Process demands- Flow or temp changes
bull Oversized equipment ndash excess surface area
Effects of System Stall
bull Inadequate condensate drainage
bull Water hammer (Thermal Shock)
bull Frozen coils damaged tube bundles
bull Poor temperature control
bull Control valve hunting ndash control stability
bull Reduction in heat transfer capacity
Pumping Condensate
bull Whatrsquos unique about condensatebull High temperature fluid
bull Constant phase change or flashing
bull Intermittent supply inconsistent suction head
2 Types of Condensate Pumps1 Electric Pumps
2 Pressure-Powered Pumps
Electric Pump Operation
What does a lower pressure due to the boiling pointLowers saturation pointGenerates flash steamFlash steam causes cavitation
Vent = Energy Loss
What is Flash Steam
Flash Capacity Calculation
Return amp Vent Sizing
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Stall Chart
StallPump Mode
Trap Mode
65 = Stallof Load Point
What does a stall chart not take into consideration
Domestic Hot Water
15 PSIG Steam Supply 250F
40F to 140F 100 GPM
0 PSIG Back-Pressure 212F
(aka Gravity-Drain)
After HX is selectedhellipnow the real world
For real-world conditions
Q = U x A x ∆T where U = K (dx)
Domestic WaterFlow Rate Varies with demand typically low to no flow in evening hours
Building HeatFlow rate varies with VFDs responding to demand
Less flow requires less flow of heat (Q)
Domestic WaterIncoming water temperature rises in summer months
Building HeatOutside Air Temperature rises is summer months
Both reduce ∆T requiring less flow of heat
Saturated Steam Table
Actual Stall Conditions40F to 140F 100 GPM using 15 PSIG Steam Supply
Heat Load Summary - Calculating Stall
Flow Rate (GPM)
Heat Load(BTUhr)
Steam Tempin HX
(F)
Steam Pressurein HX(PSIG)
Latent Heat of Steam(BTUs)
Steam amp Condensate Flow
(lbshr)
Trap Differential
(ΔP)
System Condition
100 5004000 2455 1287 9486 5275 1287 Trap Mode
95 4753800 2377 927 9538 4984 927 Trap Mode
85 4253400 2222 325 9638 4413 325 Trap Mode
75 3753000 2066 -149 9737 3854 -149 Stall - Pump Mode
65 3252600 1911 -512 9832 3308 -512 Stall - Pump Mode
50 2502000 1678 -899 9974 2509 -899 Stall - Pump Mode
25 1251000 1289 -1253 10203 1226 -1253 Stall - Pump Mode
15 750600 1133 -1329 10297 729 -1329 Stall - Pump Mode
10 500400 1056 -1357 10337 484 -1357 Stall - Pump Mode
5 250200 978 -1381 10381 241 -1381 Stall - Pump Mode
Reasons for System Stall
bull Overly conservative fouling factors during HEX design ndash adds additional surface area
bull Back pressure at equipment discharge ndash elevation or static pressure
bull Modulating Control ndash Steam pressure
bull Vacuum
bull Process demands- Flow or temp changes
bull Oversized equipment ndash excess surface area
Effects of System Stall
bull Inadequate condensate drainage
bull Water hammer (Thermal Shock)
bull Frozen coils damaged tube bundles
bull Poor temperature control
bull Control valve hunting ndash control stability
bull Reduction in heat transfer capacity
Pumping Condensate
bull Whatrsquos unique about condensatebull High temperature fluid
bull Constant phase change or flashing
bull Intermittent supply inconsistent suction head
2 Types of Condensate Pumps1 Electric Pumps
2 Pressure-Powered Pumps
Electric Pump Operation
What does a lower pressure due to the boiling pointLowers saturation pointGenerates flash steamFlash steam causes cavitation
Vent = Energy Loss
What is Flash Steam
Flash Capacity Calculation
Return amp Vent Sizing
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
After HX is selectedhellipnow the real world
For real-world conditions
Q = U x A x ∆T where U = K (dx)
Domestic WaterFlow Rate Varies with demand typically low to no flow in evening hours
Building HeatFlow rate varies with VFDs responding to demand
Less flow requires less flow of heat (Q)
Domestic WaterIncoming water temperature rises in summer months
Building HeatOutside Air Temperature rises is summer months
Both reduce ∆T requiring less flow of heat
Saturated Steam Table
Actual Stall Conditions40F to 140F 100 GPM using 15 PSIG Steam Supply
Heat Load Summary - Calculating Stall
Flow Rate (GPM)
Heat Load(BTUhr)
Steam Tempin HX
(F)
Steam Pressurein HX(PSIG)
Latent Heat of Steam(BTUs)
Steam amp Condensate Flow
(lbshr)
Trap Differential
(ΔP)
System Condition
100 5004000 2455 1287 9486 5275 1287 Trap Mode
95 4753800 2377 927 9538 4984 927 Trap Mode
85 4253400 2222 325 9638 4413 325 Trap Mode
75 3753000 2066 -149 9737 3854 -149 Stall - Pump Mode
65 3252600 1911 -512 9832 3308 -512 Stall - Pump Mode
50 2502000 1678 -899 9974 2509 -899 Stall - Pump Mode
25 1251000 1289 -1253 10203 1226 -1253 Stall - Pump Mode
15 750600 1133 -1329 10297 729 -1329 Stall - Pump Mode
10 500400 1056 -1357 10337 484 -1357 Stall - Pump Mode
5 250200 978 -1381 10381 241 -1381 Stall - Pump Mode
Reasons for System Stall
bull Overly conservative fouling factors during HEX design ndash adds additional surface area
bull Back pressure at equipment discharge ndash elevation or static pressure
bull Modulating Control ndash Steam pressure
bull Vacuum
bull Process demands- Flow or temp changes
bull Oversized equipment ndash excess surface area
Effects of System Stall
bull Inadequate condensate drainage
bull Water hammer (Thermal Shock)
bull Frozen coils damaged tube bundles
bull Poor temperature control
bull Control valve hunting ndash control stability
bull Reduction in heat transfer capacity
Pumping Condensate
bull Whatrsquos unique about condensatebull High temperature fluid
bull Constant phase change or flashing
bull Intermittent supply inconsistent suction head
2 Types of Condensate Pumps1 Electric Pumps
2 Pressure-Powered Pumps
Electric Pump Operation
What does a lower pressure due to the boiling pointLowers saturation pointGenerates flash steamFlash steam causes cavitation
Vent = Energy Loss
What is Flash Steam
Flash Capacity Calculation
Return amp Vent Sizing
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Saturated Steam Table
Actual Stall Conditions40F to 140F 100 GPM using 15 PSIG Steam Supply
Heat Load Summary - Calculating Stall
Flow Rate (GPM)
Heat Load(BTUhr)
Steam Tempin HX
(F)
Steam Pressurein HX(PSIG)
Latent Heat of Steam(BTUs)
Steam amp Condensate Flow
(lbshr)
Trap Differential
(ΔP)
System Condition
100 5004000 2455 1287 9486 5275 1287 Trap Mode
95 4753800 2377 927 9538 4984 927 Trap Mode
85 4253400 2222 325 9638 4413 325 Trap Mode
75 3753000 2066 -149 9737 3854 -149 Stall - Pump Mode
65 3252600 1911 -512 9832 3308 -512 Stall - Pump Mode
50 2502000 1678 -899 9974 2509 -899 Stall - Pump Mode
25 1251000 1289 -1253 10203 1226 -1253 Stall - Pump Mode
15 750600 1133 -1329 10297 729 -1329 Stall - Pump Mode
10 500400 1056 -1357 10337 484 -1357 Stall - Pump Mode
5 250200 978 -1381 10381 241 -1381 Stall - Pump Mode
Reasons for System Stall
bull Overly conservative fouling factors during HEX design ndash adds additional surface area
bull Back pressure at equipment discharge ndash elevation or static pressure
bull Modulating Control ndash Steam pressure
bull Vacuum
bull Process demands- Flow or temp changes
bull Oversized equipment ndash excess surface area
Effects of System Stall
bull Inadequate condensate drainage
bull Water hammer (Thermal Shock)
bull Frozen coils damaged tube bundles
bull Poor temperature control
bull Control valve hunting ndash control stability
bull Reduction in heat transfer capacity
Pumping Condensate
bull Whatrsquos unique about condensatebull High temperature fluid
bull Constant phase change or flashing
bull Intermittent supply inconsistent suction head
2 Types of Condensate Pumps1 Electric Pumps
2 Pressure-Powered Pumps
Electric Pump Operation
What does a lower pressure due to the boiling pointLowers saturation pointGenerates flash steamFlash steam causes cavitation
Vent = Energy Loss
What is Flash Steam
Flash Capacity Calculation
Return amp Vent Sizing
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Actual Stall Conditions40F to 140F 100 GPM using 15 PSIG Steam Supply
Heat Load Summary - Calculating Stall
Flow Rate (GPM)
Heat Load(BTUhr)
Steam Tempin HX
(F)
Steam Pressurein HX(PSIG)
Latent Heat of Steam(BTUs)
Steam amp Condensate Flow
(lbshr)
Trap Differential
(ΔP)
System Condition
100 5004000 2455 1287 9486 5275 1287 Trap Mode
95 4753800 2377 927 9538 4984 927 Trap Mode
85 4253400 2222 325 9638 4413 325 Trap Mode
75 3753000 2066 -149 9737 3854 -149 Stall - Pump Mode
65 3252600 1911 -512 9832 3308 -512 Stall - Pump Mode
50 2502000 1678 -899 9974 2509 -899 Stall - Pump Mode
25 1251000 1289 -1253 10203 1226 -1253 Stall - Pump Mode
15 750600 1133 -1329 10297 729 -1329 Stall - Pump Mode
10 500400 1056 -1357 10337 484 -1357 Stall - Pump Mode
5 250200 978 -1381 10381 241 -1381 Stall - Pump Mode
Reasons for System Stall
bull Overly conservative fouling factors during HEX design ndash adds additional surface area
bull Back pressure at equipment discharge ndash elevation or static pressure
bull Modulating Control ndash Steam pressure
bull Vacuum
bull Process demands- Flow or temp changes
bull Oversized equipment ndash excess surface area
Effects of System Stall
bull Inadequate condensate drainage
bull Water hammer (Thermal Shock)
bull Frozen coils damaged tube bundles
bull Poor temperature control
bull Control valve hunting ndash control stability
bull Reduction in heat transfer capacity
Pumping Condensate
bull Whatrsquos unique about condensatebull High temperature fluid
bull Constant phase change or flashing
bull Intermittent supply inconsistent suction head
2 Types of Condensate Pumps1 Electric Pumps
2 Pressure-Powered Pumps
Electric Pump Operation
What does a lower pressure due to the boiling pointLowers saturation pointGenerates flash steamFlash steam causes cavitation
Vent = Energy Loss
What is Flash Steam
Flash Capacity Calculation
Return amp Vent Sizing
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Reasons for System Stall
bull Overly conservative fouling factors during HEX design ndash adds additional surface area
bull Back pressure at equipment discharge ndash elevation or static pressure
bull Modulating Control ndash Steam pressure
bull Vacuum
bull Process demands- Flow or temp changes
bull Oversized equipment ndash excess surface area
Effects of System Stall
bull Inadequate condensate drainage
bull Water hammer (Thermal Shock)
bull Frozen coils damaged tube bundles
bull Poor temperature control
bull Control valve hunting ndash control stability
bull Reduction in heat transfer capacity
Pumping Condensate
bull Whatrsquos unique about condensatebull High temperature fluid
bull Constant phase change or flashing
bull Intermittent supply inconsistent suction head
2 Types of Condensate Pumps1 Electric Pumps
2 Pressure-Powered Pumps
Electric Pump Operation
What does a lower pressure due to the boiling pointLowers saturation pointGenerates flash steamFlash steam causes cavitation
Vent = Energy Loss
What is Flash Steam
Flash Capacity Calculation
Return amp Vent Sizing
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Effects of System Stall
bull Inadequate condensate drainage
bull Water hammer (Thermal Shock)
bull Frozen coils damaged tube bundles
bull Poor temperature control
bull Control valve hunting ndash control stability
bull Reduction in heat transfer capacity
Pumping Condensate
bull Whatrsquos unique about condensatebull High temperature fluid
bull Constant phase change or flashing
bull Intermittent supply inconsistent suction head
2 Types of Condensate Pumps1 Electric Pumps
2 Pressure-Powered Pumps
Electric Pump Operation
What does a lower pressure due to the boiling pointLowers saturation pointGenerates flash steamFlash steam causes cavitation
Vent = Energy Loss
What is Flash Steam
Flash Capacity Calculation
Return amp Vent Sizing
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Pumping Condensate
bull Whatrsquos unique about condensatebull High temperature fluid
bull Constant phase change or flashing
bull Intermittent supply inconsistent suction head
2 Types of Condensate Pumps1 Electric Pumps
2 Pressure-Powered Pumps
Electric Pump Operation
What does a lower pressure due to the boiling pointLowers saturation pointGenerates flash steamFlash steam causes cavitation
Vent = Energy Loss
What is Flash Steam
Flash Capacity Calculation
Return amp Vent Sizing
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Electric Pump Operation
What does a lower pressure due to the boiling pointLowers saturation pointGenerates flash steamFlash steam causes cavitation
Vent = Energy Loss
What is Flash Steam
Flash Capacity Calculation
Return amp Vent Sizing
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
What is Flash Steam
Flash Capacity Calculation
Return amp Vent Sizing
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Flash Capacity Calculation
Return amp Vent Sizing
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Return amp Vent Sizing
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Standard Vent Size on Electric Pump Receivers
Too Small
Not designed for flash steam
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Sub-Cooling - Avoid Cavitation
bull Flash additional energy upstream away from mechanical pumps
bull Sub-Cool condensate to 190 F before entering pump receiver
bull High amp Medium Pressure Condensate provide options for Heat Recovery
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
What do we GainLose from Sub-Cooling
Lose28 BTUslb of Condensate 15 PSIG87 BTUslb of Condensate 60 PSIG135 BTUslb of Condensate 125 PSIG
Gain25 of Potential Dissolved Oxygen
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
How do we Remove the Flash Vent
Use a Pressure PumpUp to 400 F
No Energy Loss
Does not require Sub-Cooling of Condensate
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Pressure Pump amp Steam Trap Combo
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Pump-Trap Combo w Single Float Mechanism
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Stall Alleviation
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Closed-Loop System
Heat Exchanger stays dry 100 of the time
1 HX reaches temperature or demand stops
2 Control Valve Shutsbull 0 PSIG Steam Supplybull Lose Positive Differential
Pressure3 Steam within System
Condensesbull Draws a vacuumbull More efficient heat
exchange4 Pumps
bull Create Positive Differential Pressure
bull Maintains Vacuum Conditions
Off ndash 0 PSIG Steam Supply
Vacuum1000+ BTUslb of Steam
GravityDrain
Power SupplyMotive
SteamAirNo Electrical
Power
125 PSIG280 ft + of Lift
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Typical InstallationOpen-Loop Gravity-Drain Design
125 HPS
10 LPC
Roof
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
125 HPS
10 LPC
Roof
15 HPS
Closed-Loop Feed-Forward Design
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Closed-Loop Pump-Trap Design
125 HPS
10 LPC
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Condensate Pump Application Considerations
1 Will there be lift after the steam trap
2 Will there be variable process conditions
3 Will the leaving process conditions temperature be equal or less than 212degF
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
System Stall Solutions
Installation of a vacuum breaker
Objective
To relieve a vacuum within equipment allowing for condensate drainage
Shortcoming
This practice will only help if the condensate is gravity drain to atmosphere
Allows undesirable air into the system
Vacuum breakers often fail due to a poorly chosen location
Loss of valuable flash steam
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Installation of a safety drainObjectiveThe use of a second steam trap located above the primary trap which discharges condensate to drain when the system goes into a stall condition ShortcomingA significant amount of condensateflash steam and valuable BTUrsquos are lost down the drain when the system is in stall Stall load may be as high as 90 or more of the design load therefore 90 of thecondensate coming from the equipment goes down the drain
System Stall Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Installation of a positive pressure system
Objective
The use of air or other gas to maintain set pressure to ensure a positive pressure differential across the trap allowing for condensate drainage
Shortcomings
Injects a significant amount of undesirable air into the equipment This large amount of air may cause multiple problems
Air acts as an insulator thereby decreasing the heat transfer capacity of the equipment
A heavy dependence on air vents to evacuate the air from the equipment
Air vents may be open a significant amount of time allowing for loss of valuable BTUrsquos
System Stall Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Closed Loop Condensate System
The application of a ldquoclosedrdquo system pump trap on your modulating steam equipment can provide the following benefits
Continuous condensate drainage even in a vacuum
Eliminates the need for vacuum breakers
Saves valuable flash steam from escaping into the atmosphere
No need to run expensive vent lines
No rotating seals cavitation or NPSH requirements
Negligible operating cost
Longer equipment life
Reduced corrosion
Better temperature control
Shortcomings Relative costs versus conventional systems
System Stall Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Spot the issue
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
How did this end up this way
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
If we donrsquot fix it add onhellip
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Done right with forethought
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Recap
bull By design heat exchange equipment have excess surface area
bull Condensate must flow from a higher pressure to a lower pressure ndash account for this in design
bull Air and non ndashcondensable gases need to be managed along with flash steam in the condensate system
bull Whenever you have modulating steam pressure for temperature control the potential for system stall exists
bull Electric condensate pump receivers are not used as flash tanks
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
How well did I do
1 Identify two types of heat transfer2 In the equation Q = U x A x ∆T - Define U Define A3 Define the general definition of ldquosystem stallrdquo4 When lowering the pressure of condensate in system we create5 Heat exchangers typically have surplus surface area ndash TF6 A flash tank in front of an electric condensate pump is a good idea ndash
TF7 Reducing the effects potential for system stall will improve ndash List
three items8 List three consideration where you may want to incorporate a
condensate pumping system
Selection Expertise Solutions
Selection Expertise Solutions