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Broaden Your Knowledge about Condensate Pot

Saeid Rahimi
30-Nov-2011
Introduction
Steam condensate recovery is an essential requirement for enhancing
the overall performance, reducing the operation cost and having
trouble free operation of steamheated shell and tube heat
exchangers. Energy consciousness and environmental awareness
have transformed condensate from an inexpensive byproduct of
steam distribution to a valuable resource that can substantially
reduce operating costs. From plant operation point of view, effective
condensate removal guarantees smooth operation, no hammering and
reduced corrosion as well.
This note briefly reviews the various options used in steam
condensate recovery system and focuses on the condensate pots
design and operational considerations. Figure 1 Effect of Heat Exchanger Flooding
Importance of Condensate Recovery
Successful removal of condensate is a key factor in preventing stall, a phenomena that is often observed during operation of
steam-heated heat exchangers. In short, stall prevents condensate from being discharged from the heating equipment. It
occurs when the steam pressure in heating equipment drops below condensate header pressure causing condensate reverse
flow and flooding heat exchanger with condensate.
During normal operation, the supply of steam
(controlled by pressure of flow control valve)
ensures that the pressure inside the heat exchanger
is high enough to efficiently drain the condensate
to the condensate header. However, when the
demand for steam is reduced, steam control valve
starts closing to match the heating requirement.
This will reduce the pressure in heat exchanger and
this may be too low to enable efficient discharge of
steam condensate. If the heat exchanger pressure
drops to condensate header pressure or below,
condensate then backs up in the heat exchanger,
and the equipment becomes condensate logged.
This condition is known as stall. When condensate
is backed up inside the equipment the product
temperature falls. The control system compensates
by opening the steam control valve again. Steam
pressure increases and when it becomes greater
than condensate pressure, condensate is pushed out
of the system, and the cycle begins again. Figure 2 Process Control via Steam Temperature Manipulation
This results in:
Process Temperature Swing; as the stall cycle repeats, the steam pressure in the equipment varies above and below the
backpressure causing product temperature and quality to fluctuate.
Water Hammer Damage; water hammer can occur when backed-up condensate re-evaporates, or as the incoming
hotter steam comes in contact with cooler backed-up condensate and is instantly condensed.
Tube Corrosion and Damage; backed-up condensate in the equipment can form carbonic acid, which results in tube
corrosion. Equipment temperature fluctuations can cause thermal shock and fatigue damage to the tubes.
Correct design of condensate recovery system including proper selection of condensate recovery device, equipment sizing
and using right control system configuration will help to prevent these problems.

Process Control Strategies

There are two mechanisms for controlling heat transfer rate (U A T). The first mechanism is to change heat transfer rate by
changing the steam temperature (T). With a control valve on steam supply, changing the valve position affects the heating
fluid pressure and its corresponding temperature, which affects the heat transfer rate. When this mechanism is used along
with steam trap or condensate pot with level control, heat exchanger is subject to back flooding and associated problems
mentioned in previous section.
The second mechanism is to change the heat transfer area (A). With a control valve on condensate return (Figures 2 or 3),
manipulating the valve position affects the effective heat transfer area of the exchanger. The effective area for heat transfer is
the heat transfer surface exposed to steam; the submerged surface area has little contribution to the total heat transfer rate.
With this configuration, heat exchanger tubes are intentionally flooded to control the process temperature. Heat exchangers
are usually designed with limited area overdesign (typically 10%), therefore slight flooding should be enough for control
purpose. Further flooding is required when heat exchanger is clean or in turn down condition. Heat exchangers with
substantial area overdesign will suffer from flooding side effects during normal operation.
Condensate Recovery Devices
In any steam distribution system in a process plant,
the condensate requires some means to guarantee
continuous drainage of condensate. The most
common means are:
Steam Trap
Condensate Pot
Condensate Pump
Pump Trap
Steam Trap: Steam traps are widely employed to
drain condensate and vent non-condensable gases
from heat exchangers. Because of the internal
mechanism, steam traps drain liquid once it is
condensed and keeps all heat exchanger area
available for heat transfer. Figure 3 - Process Control via Heat Transfer Area Manipulation
Condensate Pot: The condensate level in the collection pot can be controlled using independent level controller or
temperature-level cascade controller. The level controller version incorporates a modulating steam valve for process side
temperature control (Figure 2), whereas the temperature-level cascade controller system uses a constant pressure steam valve
and varies the exposed heat exchanger surface area by flooding the vessel with condensate (Figure 3). While both options
provide process temperature control, neither is without potential performance and equipment integrity problems.
Condensate Pump: Using conventional centrifugal or positive
displacement pumps with a condensate receiver at suction can be
an option where other alternatives are ruled out.
Pump Trap: Incorporating a mechanically actuated pumping
device driven by air, other gas, or steam, called a pump trap, is
another alternative (Figure 4). This approach allows the heat
exchanger to operate at its lowest possible pressure while
maintaining a consistent outlet process temperature profile
minimizes energy consumption. Complete, effective removal of
condensate under all operating conditions allows a heat
exchanger to operate with minimum corrosion on the tube
bundle, assuring its structural integrity by lessening the potential
for destructive water hammer. Compared to conventional pumps,
pump traps can often lead to significant capital cost savings, by
reducing the skirt height required for exchangers or reboilers,
sometimes to as little as 4 ft. Figure 4 Pump Trap Piping Arrangement
Table-1 represents the advantage and disadvantage of various condensate recovery devices.

Table 1- Condensate Recovery Device Comparison

Device Advantage Disadvantage
Steam trap 1- Inexpensive
2- Simple installation with minimum piping
and instrumentation
1- Needs periodical maintenance to prevent
failure causing steam break-through and
steam hammering
2- Allows condensate to back up and flood
the heat exchanger causing loss of thermal
performance, corrosion and water hammer
Condensate pot with
independent level
control
1- Manual adjustment of heat exchanger
surface area to match with actual thermal
requirements
1- Costlier than steam trap with more piping
and instrumentation devices
2- Same as item 2 in steam trap
3- Needs operator intervention to change level
control set point with respect to heating
requirement
Condensate pot with
level control
cascaded with
process temperature
1- Automatic adjustment of heat exchanger
surface area to match with actual thermal
requirements
2- Prevents unintentional flooding as
condensate pot pressure is kept always
above condensate header pressure
1- Same as item 1 in condensate pot with
independent level control
2- Since heating equipment flooding is
required for process control reasons,
corrosion still exists.

Condensate Pump

1- No flooding as it will send the condensate
even with heat exchanger working at a
pressure lower than condensate header
2- No tube corrosion and water hammer and
thermal shock
1- Costlier than condensate pot
2- NPSHA requirement may dictate highly
elevated heat exchanger at suction
3- Rotating machines need more maintenance
due to seal, bearing and impeller damage
Pump Trap 1- Same as item 1 in condensate pump
2- Same as item 2 in condensate pump
3- Needs substantially lower static head at
suction (NPSHA) to operate compared to
condensate pump
1- Same as item 1 in condensate pump
Condensate Pot Sizing
Sizing of pot is has a close relation to heat exchanger thermal rating and hydraulic calculations.
Step 1- Calculate the condensate pot diameter; A = Q T
1
/ S
Where
T
1
= 1 - 1.5 minutes

S = H
1
+ H
2
(min 300mm)
Neglecting the pressure drop of piping and heat exchanger during turn down condition, the height of liquid in condensate pot
required to achieve proper process control can be estimated using below relation. Due to this assumption, the liquid level in
the pot will be slightly lower than H
1
.
H
1
= (1- Turndown Percentage/100) * C
For horizontal heat exchanger, C = tube bundle diameter
For vertical heat exchanger, C = tube bundle length
H
2
= (P piping + P heat exchanger) / (
L
g)
Piping include steam line from vapor balancing line connection to heat exchanger inlet nozzle and condensate outlet line
from heat exchanger outlet nozzle to pot inlet nozzle or liquid balancing line connection.

The calculated (not allowable) pressure drop of steam side of heat

exchanger at designed flow and fouled condition is used for this
calculation. Since steam side is categorized as condensing service,
steam side pressure drop should not be negligible.
Calculated diameter can be rounded up to the next nominal pipe
internal diameter if it is going to be constructed from pipe. In
order to have adequate mechanical strength, minimum supporting
problems and proper nozzle opening on condensate pot, it is
recommended no to use pot with diameter less than 500mm.
Step 2- Calculate the condensate pot length;
L = C + H
2
+ H
3
+ H
4
+ H
5
+ H
6
Where
H
3
= Q T
2
/ A
T
2
= 1 minute Providing 1 minute between NLL and LLL will
ensure that steam wont blow into condensate system because of
level control action, process or steam fluctuations, causing steam
hammering.
If there is low-low level trip, H
4
= 200 mm (100 mm min)
otherwise H
4
= 0
To accommodate level instrument tapping, H
5
= 300 mm.
The condensate pot level is not expected to exceed H
1
in any
operating condition (ranged from turndown to design condition,
clean to fouled heat exchanger) as long as condensate is flowing
and everything is under control. In view of this, setting the pot top
TL with top of the heat exchanger tube sheet should be enough
for operational and troubleshooting purposes (H
6
= 0). However,
the most conservative approach may be is to provide H
6
of 300
mm.
Design Details
P&ID Representation
One of the main inputs from pot sizing calculations to P&D is the static head difference between heat exchanger bottom and
condensate pot bottom TL which can be calculated as follow.
X = H
2
+ H
3
+ H
4
+ H
5

Condensate Line Size
Adequately sized condensate line should ensure:
1) Minimum pressure drop which reduces the differential static head between heat exchanger and pot TLs. This is
important to reduce the size of pot and heat exchanger elevation from grade.
2) Self venting flow in the heat exchanger condensate outlet line. Presence of gas bubbles in the outlet condensate will
reduce the density of liquid and cause liquid to expand and fill the heat exchanger. In this case, though condensate pot
level is accurately controlled, but system is exposed to detrimental effects of flooding. In summary, for pipe equal and
larger than 1 handling a fluid with viscosity less than 100cp, vapor bubbles can freely rise if liquid velocity is
maintained less than the velocity calculated from below equation:
ABBREVIATION
A Condensate pot area
C Heat exchanger characteristic dimension
d Condensate line internal diameter, m
D Condensate pot diameter
L Condensate pot length
g Acceleration of gravity, 9.81 m/sec
2

H
1

Distance between heat exchanger bottom to
flooded level in pot
H
2

Distance between bottom of tube bundle to
pot NLL
H
3
Distance between pot NLL to LLL
H
4
Distance between pot LLL to LLLL
H
5
Distance between pot LLLL to bottom TL
H
6

Distance between top of heat exchanger
tube bundle to pot top TL
LLL Low liquid level in pot
LLLL Low-low liquid level in pot
NLL Normal liquid level in pot
HLL High liquid level in pot
HHLL High-high liquid level in pot
Q Condensate volumetric flow rate
S Condensate level span
T Hold up time
TL Tangent line
V Fluid velocity, m/sec
P Pressure drop
X
Differential head between heat exchanger
b tt d t b tt TL

Fluid density

I = u.S1 _g J _
p
L
-p
g
p
L
]
Where
L
and
g
are condensate and steam densities respectively.
Vapor Balancing Line
The purpose of vapor balancing line, as its name implies, is to equalize the pressure of condensate pot with heating
equipment, prevent vapor blanketing the condensate pot and minimize the static head difference between liquid level in the
heat exchanger and corresponding level in pot (H
2
).
Vapor balancing line is not going to pass any specific flow rate; hence any size between 1 to 3 would be enough for this
purpose.
Condensate Line Piping Arrangement
Since heat exchanger flooding may create sub-cooled condensate, it is recommended to locate the condensate inlet close to
pot bottom TL so that sub-cooled condensate exits out of the bottom of the pot without reaching the liquid surface (NLL) as
shown in Figure 3. With adequately sized pressure balancing line, pot liquid surface is kept hot, and the pot pressure will
remain at vapor pressure of hot liquid. As long as the liquid in the upper part of the pot is not agitated and does not contact
the sub-cooled condensate, the flow of steam through a typically 1 equalizing line is sufficient to compensate system heat
losses to ambient and heat transfer from hot surface to the sub-cooled condensate.
Another alternative is to connect the heat exchanger condensate line to the pot condensate outlet line as depicted in Figure 2.
This arrangement may result in slightly longer pipe, higher pressure drop and subsequently bigger H
2
.
Contact
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