2000 Hook-up Book

Condensate Recovery Systems

Pumped Return Lines Finally, the condensate is often pumped from the receiver to the boiler plant. These pumped con densate lines carry only water, and rather higher water velocities can often be used so as to mini mize pipe sizes. The extra friction losses entailed must not increase back pressures to the point where the pump capacity is affected. Table 35 (page 77) can be used to help estimate the frictional resistance presented by the pipes. Commonly, velocities in pumped returns should be limited to 6-8 ft./sec. Electric pumps are commonly installed with pumping capability of 2-1/2 or 3 times the rate at which condensate reaches the receiver. This increased instanta neous flow rate must be kept in mind when sizing the delivery lines. Similar considerations apply when steam powered pumps are used, or appropriate steps taken to help attain con stant flow along as much as possible of the system. Where long delivery lines are used, the water flowing along the pipe as the pump discharges attains a considerable momen tum. At the end of the discharge cycle when the pump stops, the water tends to keep moving along the pipe and may pull air or steam into the delivery pipe through the pump outlet check valve. When this bubble of steam reaches a cooler zone and condenses, the water in the pipe is pulled back towards the pump. As the reversed flow reaches and closes the check valve, waterhammer often results. This problem is greatly reduced by adding a sec ond check valve in the delivery line some 15 or 20 ft. from the pump. If the line lifts to a high level as soon as it leaves the pump, then adding a generously sized vacuum breaker at the top

of the riser is often an extra help. However, it may be necessary to provide means of venting from the pipe at appropriate points, the air which enters through the vac uum breaker. See Figures II-71 and II-72 (page 118). The practice of connecting additional trap discharge lines into the pumped main is to be avoided whenever possible. The flash steam which is released from this extra condensate leads to thermal shock creating a bang ing noise within the piping commonly associated with water hammer. The traps should discharge into a separate gravity

line which carries the condensate to the receiver of the pump. If this is impossible, a second best alternative may be to pipe the trap discharge through a sparge or diffuser inside the pumped return line. The trap most suitable for this application would be the Float and Thermostatic type due to its continuous discharge. This is very much a compromise and will not always avoid the noise (see Fig. 53 and 53A) although it will reduce the severity.

SYSTEM DESIGN

Discharge from Trap

Condensate Return

Figure 53 Discharge of Steam Trap into Pumped (flooded) Return Line using Sparge Pipe.

Thermo Dynamic

Steam Trap with Integral Strainer

Trap Diffuser

Spira-tec Loss Detector

Figure 53A Discharge of Steam Trap into Pumped (flooded) Return Line using a Trap Diffuser.

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