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Condensate return systems can have a big impact on productivity, energy efficiency, and site reliability. Use this guide to better understand your condensate return, optimize its operation, and mitigate common pitfalls such as high backpressure and water hammer.
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To improve steam system efficiency and reliability, engineers often focus primarily on the steam supply side, addressing problems such as piping leaks, steam trap leaks, and corrosion under insulation. The conversation rarely shifts to improvement opportunities in the condensate return system, unless significant issues already exist - such as high backpressure, or knocking and the pipe damage it can cause. Plant personnel are typically most concerned with steam supply and the heat that it provides to the manufacturing units, but a condensate return system can have significant impact on production, efficiency, and reliability.
If you are maintaining a sports car, you may be concerned with the fuel quality, injection method, and ignition, but the car will not function well if the exhaust system is compromised or subpar. Exhausted fuel must discharge freely in order for the car to operate effectively. Steam equipment has the same requirement - it must be able to discharge condensate freely.
Although many experienced engineers know a substantial amount about handling steam, there appears to be less understanding of condensate systems, their design, and the many factors that affect their performance. This article discusses those influences, and describes the causes of detrimental effects and possible responses to achieve morereliable performance. It also gives readers insight into these common questions:
* What causes water hammer in condensate systems? How can site personnel identify the conditions that cause system hammering?
* How do leaking steam traps affect the return system?
* What effect do outlet control valves designed to discharge condensate from steam equipment have on the return system?
* How are condensate lines sized for nonflashing systems, and how does that differ from sizing returns when flash steam is involved?
* How are pumped condensate return lines handled, and how does that differ from the way flashing condensate return lines are handled?
* What is the effect of cushioning water-hammered condensate systems with steam or nitrogen?
* How do vertical lifts affect condensate lines?
Types of condensate return...