DB-S78-05
ST Issue 2
Solving the condensate pumping problem
Pumps, as a rule, are reliable and trouble free - but the pumping of condensate too often
proves to be the exception. However steam-powered pumps can help.
This article first appeared in 'Process Engineering'
and is reprinted by kind permission of the Editor.
The pumping of hot condensate is a problem that
confronts a lot of process operators. Most engineers
opt for the traditional electrically operated centrifugal
pump, which performs so well in other applications,
but too often find that it is unable to cope
economically with handling condensate.
The main reason for this poor performance in such
an application is the condensate itself. Usually the
condensate flows under gravity from the steam trap
to a receiver, from where it should be pumped away
without problems. But to assist the gravitationally
propelled flow of condensate, the receiver and pump
are often located in a pit; a location which is
susceptible to flooding, hampering the operation of
electrical pumps.
Another problem which faces conventional pumps
in condensate applications is that the condensate
frequently arrives at the receiver as a mixture of
condensate and flash steam - the latter leaving
boiling water when released through the receiver
vent. Subjecting this to the reduced pressure
experienced at the inlet to a centrifugal pump
lowers the boiling point, causing the formation of
more flash steam, which chokes the pump, reduces
its capacity and cuts effective performance of
the system.
At the same time, cavitation - the collapse of steam
bubbles within the pump impeller - causes serious
pitting corrosion on the inside of the pump.
Far from ideal
These three problems mean that, although
conventional pumps can be used to handle
condensate, they are far from the most efficient
method available.
Of course, measures have been taken to overcome
these problems by improved cascade control and
supplying pumps in pairs, so that there is a back-up
if one pump fails or capacity needs to be increased.
But a more radical and cost effective alternative
exists in the form of the pressure powered pump,
which use steam or compressed air as the operating
medium. These have been around for some
time, but are now beginning to attract more
wide-spread interest from condensate pumpers.
The attraction of this type of pump is its sheer
simplicity. There are no seals to maintain and its
few, slow moving parts are not subject to excessive
wear. The use of steam as the motive force removes
the need for electricity, simplifying both installation
and maintenance.
The benefits of such pumps become even more
apparent when compared directly against electrical
sets in use in condensate pumping.
Since the pumps require no electricity they can
be used safely in the wettest environments. The
pump will continue to operate when completely
flooded, though steam consumption will increase. It
is also important to note that when operated by
compressed air, the pumps can be used as fully
submerged sump pumps.
The devices also obviate the need for the
complicated level control systems often found with
electrical pump sets as they operate only when
there is condensate being pumped, because they
are powered by the steam itself.
Advantages also exist in terms of efficiency with
the displacement pump offering clear economic
advantage. Most electrical energy is generated at
an efficiency of around 40 percent. Steam operated
pumps derive their energy from fuel burned at over
80 percent efficiency.
In some situations these economics can be further
enhanced by making sensible use of exhaust steam-
and such mini-CHP schemes are increasingly
attractive with the rise of green issues.

Indeed, in Berlin, New Hampshire in the north-

eastern United States, a paper mill has successfully
replaced all its electric pumps with pressure
powered pumps and accrued savings of around US
$8 500 a year in maintenance and operating costs.

This success story reflects the increasing

acceptance of pressure powered pumps in industrial
applications.

Spirax-Sarco Limited, Charlton House,

Cheltenham, Gloucestershire, GL53 8ER UK.
Tel: +44 (0)1242 521361 Fax: +44 (0)1242 573342
E-mail: Enquiries@SpiraxSarco.com
Internet: www.SpiraxSarco.com
Copyright 2004 Spirax Sarco is a registered trademark of Spirax-Sarco Limited