Pumping Condensate from Vented Receivers

A basic introduction to pumping terminology, including vapour pressure and

static head. Includes a description of the operation, application and
comparable benefits of electrical centrifugal and mechanical condensate
pumps, with sizing examples for pumps and pump discharge lines.
Pumping terminology
Vapour pressure - This term is used to define the pressure corresponding to the
temperature at which a liquid changes into vapour. In other words, it is the pressure at
which a liquid will boil.
At 100C, water will boil at atmospheric pressure.
At 170C, water will boil at a pressure of 7 bar g.
At 90C, water will boil at a pressure of 0.7 bar a.
The vapour pressure is a very important consideration when pumping condensate.
Condensate is usually formed at a temperature close to its boiling point, which may
cause difficulties where a centrifugal pump is concerned. This is because centrifugal
pumps have an area of lower pressure at the centre, or eye, of the impeller. This
produces the suction effect, which draws the liquid into the pump. Although the drop in
pressure is small, if the condensate is already very close to its vapour pressure, a
proportion of the liquid will flash to steam in the form of small bubbles. These steam
bubbles occupy a significantly greater volume than the equivalent mass of water, and
have
a
high
ratio
of
surface
area
to
mass.

As the bubbles travel through the impeller passageways towards its outer edge, they
experience increasing pressure. At some point during this journey, the vapour pressure is
exceeded, and the steam bubbles implode with considerable force. This is termed
'cavitation' and the implosions are both noisy and destructive. The noise is similar to
gravel being shovelled and the implosions will, in time, damage the pump internals.
For this reason, it is recommended that condensate be pumped by electrical pumps
specifically built for the task, and that condensate temperatures in atmospheric systems
do not exceed 98C. Some pumps will have limits as low as 94C or 96C, depending on
the design of the pump, the speed of rotation and the height of the receiver above the
pump.
Head (h) - Head is a term used to describe the potential energy of a fluid at a given
point. There are several ways that head can be measured: pressure head, static head
and friction head. Pressure head and static head are essentially the same thing, but tend
to be measured in different units. Pressure head is measured in pressure units such as
pascal or bar g; whilst static head is referred to in terms of height, usually in metres (or
metres
head).
For water, a static head of 10 metres is approximately equivalent to a pressure head of 1
bar
g
(see
Figure
14.4.1).
Pressure head (hp) - Pressure head is the fluid pressure at the point in question. For
Page 1 of 24

example: A pump is required to discharge water against a static head of 30 metres,

which approximately equals a pressure head of 3 bar g. The pump fills from a static head
of 1 metre, which equals a pressure head of 0.1 bar g. (See Figure 14.4.2).
Static head (hs) - Static head is the equivalent vertical height of fluid above a datum.
The following example explains the measure of static head. Example: the pump inlet in
Figure 14.4.2 is subjected to a static head (known as the suction or filling head) of 1 m,
and discharges against a static head (known as the static delivery head) of 30 m. Note
that in this case, the water being pumped is above the pump inlet (this situation is called
a flooded suction).

Fig. 14.4.1 Pressure of water in terms of

head

Fig.

14.4.2

Suction,

delivery, and filling heads

Net static head - This depends upon whether the pump is a centrifugal type pump or a
positive
displacement,
mechanical
type
pump.
With an electrical centrifugal pump (Figure 14.4.3), the pressure exerted by the suction
head is always present in the pump. The net static head, against which the pump has to
work, is the difference between the suction head and the delivery head.
Page 2 of 24

Fig. 14.4.3 Net static head

for an electrical pump
With a mechanical displacement pump (Figure 14.4.4), the suction head only provides
the energy to fill the pump during the filling cycle. It is not present in the pump body
during pumping and has no effect on the delivery head against which the pump has to
operate. The net static head is simply the delivery head.

Fig.
static head for a mechanical pump equals static delivery head

14.4.4

Net

Friction head (hf) - The friction head (or head loss to friction) is more accurately
defined as the energy required to move the fluid through the pipe. This is discussed in
further
detail
in
Tutorial
10.2,
'Pipes
and
pipe
sizing'.
Pressure loss can be calculated using the procedures shown in Block 4, 'Flowmetering'
and Block 10, 'Steam distribution', but is more usually found from tables that correlate
liquid flowrate, pipe diameter and velocity. To be precise, the resistance to flow
Page 3 of 24

encountered by the various pipeline fittings must also be taken into account. Tables are
available to calculate the equivalent length of straight pipe exerted by various pipe
fittings.
This extra 'equivalent length' for pipe fittings is then added to the actual pipe length to
give a 'total equivalent length'. However, in practice, if the pipe is correctly sized, it is
unusual for the pipe fittings to represent more than an additional 10% of the actual pipe
length.
A
Total

general
equivalent

rule,
length

which
(le)

can
=

be
Actual

applied,
length

is:
10%

In most cases, the Steam Plant Engineer will be designing a system with a proprietary
manufactured pump arrangement, which has appropriate factors built in. Bearing this in
mind, the figure of 10% will be used in this Block as the equivalent length for calculating
pressure
loss
due
to
friction.
This pressure loss due to friction is greatly dependent on the velocity of the water in the
pipe. In simple terms, the pressure loss due to friction increases by a factor proportional
to
the
square
of
the
velocity.
Tables are available which give head loss per metre of pipe for various flowrates and pipe
diameters.

Table

14.4.1

Flow of water in black steel pipes (kg/h)

Example 14.4.1
The 50 mm discharge pipework on a pumped condensate line rises vertically for 29
metres to a vented tank. The line is 150 m long and the pumping rate is 5 000 kg/h of
water.
What
is:
(A) the
pressure
head
loss
due
to
friction
(the
friction
head),
and
(B) the total delivery head?>

A - Calculate the pressure head loss due to friction (the friction head)
Total
equivalent
length
(le)
=
150
+
10
%
=
165

metres

From Table 14.4.1, it can be seen that a 50 mm pipe carrying 5 004 kg/h of water will
experience a pressure drop of 1.0 mbar/m. The flowrate in this example is marginally
less, and, although a more accurate estimate could be obtained by interpolation, take
the
pressure
drop
as
1
mbar/m.
Page 4 of 24

Pressure
165

head
metres

loss

due

mbar/m

to
=

friction
165

is
mbar (0.165

therefore:
bar)

Taking 1 bar to be equivalent to 10 metres of water head the equivalent friction head
loss
in
terms
of
metres
is:
0.165 bar x 10m/bar = 1.65 metres.
B - The total delivery head
Total delivery head (hd) - The total delivery head h d against which the pump needs to
operate is the sum of three components as can be seen in Equation 14.4.1:
Equation 14.4.1
Where:
hd =Total delivery head
hs =Pressure required to raise the water to the desired level (static head)
hf =Pressure required to move the water through the pipes (friction head)
Pressure in the condensate system (zero in this example as the condensate tank is
hp =
vented to atmosphere).

Fig. 14.4.5 Net static head for

a mechanical pump equals static delivery head
From

the

information

above:

Total delivery head (hd) required = static head + equivalent loss in static head due to
friction
hd =29

+
Page 5 of 24

1.65 m
hd =30.65 metre
Electrical centrifugal condensate pumps
Pump operation
Liquid entering the pump is directed into the centre, or eye, of the rotating impeller
vanes. The liquid will then gain velocity as it travels towards the outside of the impeller.
Pump application
The electrical pump is well suited to applications where large volumes of liquid need to
be
transported.
Electrical pumps are usually built into a unit, often referred to as a condensate recovery
unit (CRU). A CRU will usually include:
A receiver.
A control system operated by probes or floats.
One or two pumps.
When calculating the frictional loss in the discharge line for a CRU, it is the pumping rate
that must be considered as opposed to the rate of condensate returned to the receiver.

On twin pump units, a cascade control system may also be employed which allows either
pump to be selected as the lead pump and the other as a stand-by pump to provide
back-up if the condensate returning to the unit is greater than one pump can handle.
This control arrangement also provides back-up in the case of the one pump failing to
operate; the condensate level in the tank will increase and bring the stand-by pump into
operation. For cascade type units, the frictional loss in the discharge line is calculated on
the
maximum
pumping
rate
of
both
pumps
in
the
CRU.
It is very important to follow the manufacturer's literature regarding the discharge
pumping rate. Failure to do so could result in undersizing the pump discharge pipework.

Fig.
electrical condensate recovery unit (CRU)
Page 6 of 24

14.4.6

typical

Sizing an electrical condensate recovery unit

To size an electric condensate recovery unit, it is necessary to know:
The amount of condensate reaching the receiver at running load.
The temperature of the condensate. This must not exceed the manufacturer's
specified ratings to avoid cavitation, however, manufacturers usually have
different impellers to suit different temperature ranges, for example, 90C, 94C
and 98C.
The total discharge head the pump has to pump against - To be determined from
the site conditions.
The pump discharge rate in order to size the return pipework - It is necessary to
read the manufacturer's data properly to determine this.
Example 14.4.2 Sizing discharge pipework for an electric condensate recovery
unit
Where:

An initial selection of a condensate recovery unit can be made by using the

manufacturer's sizing chart (an example of which is shown in Figure 14.4.7). From the
chart, CRU1 should be the initial choice subject to frictional losses in the delivery
pipework.

Page 7 of 24

Fig. 14.4.7 A
typical electrical condensate recovery unit (CRU) sizing chart (see Example
14.4.2)
From the chart in Figure 14.4.7, it can be seen that CRU1 is actually rated to handle 3
000 kg/h of condensate against a maximum delivery head of 35 m.
The condensate return line is sized on the maximum pumping rate at the required
delivery head, which is demonstrated in the example below:
Maximum pumping rate = 3 000 kg/h
It is this figure, 3000 kg/h, that must be used to size the discharge pipework.
It is now possible to calculate the optimum size for the return line.

Estimating the friction loss in the pipe (hf)

To size a pumped discharge line it is usually a good idea to begin the friction loss
calculation with an arbitrary pressure drop of between 100 and 200 Pa/m
Page 8 of 24

From the pressure drop Table 14.4.2 (extract shown below), it can be seen that, for a
flowrate of 3 000 kg/h, and for a pressure drop of between 100 and 200 Pa/m, a 40 mm
discharge pipe will suffice.

Extract from
Table 14.4.2
It can be interpolated from Table 14.4.2 that a flowrate of 3 000 kg/h will correspond to a
pressure drop of 128 Pa/m, for 40 mm pipework,

Establishing the total delivery head

The total delivery head against which the pump has to discharge is therefore h s + hf =
hd,
where:
static lift of 30 m
hs =
(given)
hf =2.1 metres

The delivery head of 32.1 metres needs to be checked against the CRU manufacturer's
sizing chart to confirm that the unit can pump against this amount of head. It can be
seen from Figure 14.4.7 that this CRU can actually pump against a 35 metre head. Had
the design head of 35 metres been exceeded, then the options are to re-calculate using
a larger pipe, or to select a CRU with a greater lifting capacity.
An alternative way to size the delivery pipework
With an actual static head (hs) of 30 m, and a CRU design head of 35 m, a 5 m head is
available for pipe friction losses (h f). It might be possible to install a smaller diameter
pipe and have a larger friction loss. However, the designer must weigh this initial cost
saving against the extra running power (and hence cost) required to pump against a
larger
head.
Velocity also needs to be checked against a typical maximum of about 3 m/s allowable
for
pumped
water
at
temperatures
below
100C.
Table 14.4.2 will show that, if the next lower sized pipe (32 mm) were chosen, the unit
Page 9 of 24

friction loss (hf) to pass 3000 kg/h is interpolated to be 286 Pa/m, and the velocity is
about 1 m/s, which is below 3 m/s and therefore suitable for the application.

The conclusion is that a 32 mm pipe could be used, as the CRU1 pump can handle up to
35 m total delivery head. However, from a practical viewpoint, it might not be reasonable
to design a system to operate so close to its limits, and that, in this instance, 40 mm
pipe would probably be the better solution.

Page 10 of 24

Page 11 of 24

Table 14.4.2 A section of a typical friction loss table for fully flooded pipelines
(flowrates in kg/h)
Mechanical (positive displacement) condensate pumps
Pump operation
A mechanical pump consists of a body shell, into which condensate flows by gravity. The
body contains a float mechanism, which operates a set of changeover valves.
Condensate is allowed to flow into the body, which raises the float. When the float
reaches a certain level, it triggers a vent valve to close, and an inlet valve to open, to
allow steam to enter and pressurise the body to push out the condensate. The
condensate level and the float both fall to a preset point, at which the steam inlet valve
shuts and the vent valve re-opens, allowing the pump body to refill with condensate.
Check valves are fitted to the pump inlet and discharge ports to ensure correct
directional
flow
through
the
pump.
The cyclic action of the pump means that a receiver is required to store condensate
while the pump is discharging (see Figure 14.4.8).

Fig.

14.4.8

typical

mechanical

condensate recovery unit

Pump application
Generally, mechanical pumps handle smaller amounts of condensate than electrical
pumps. They are however, particularly valuable in situations where:

High condensate temperatures will cause cavitation in electrical pumps.

Condensate is in vacuum.
Plant room space is at a premium.
Low maintenance is an issue.
The environment is hazardous, humid or wet.
Electrical supplies are not at hand.
Condensate has to be removed from individual items of temperature controlled
equipment, which may be subject to stall conditions (see Block 13 'Condensate
Removal', for further details).
Page 12 of 24

As with electrically driven pumps, positive displacement mechanical pumps are

sometimes, but not always, specified as packaged condensate recovery units. A
mechanical condensate recovery unit will comprise a condensate receiver and the pump
unit. No additional control system is required as the pump is fully automatic and only
operates
when needed.
This
means
that
the
pump
is
self-regulating.
With mechanical pumps, the pump cycles as the receiver fills and empties. The
instantaneous flowrate while the pump is discharging can often be up to six times the
filling rate and it is this instantaneous discharge flowrate, which must be used to
calculate the size of the discharge pipe. Always refer to the pump manufacturer for data
on sizing the pump and discharge line. A typical mechanical pump sizing chart is shown
in Figure 14.4.10.
Sizing a mechanical condensate pump
To size a mechanical condensate pump, the following information is required:
The maximum condensate flowrate reaching the receiver.
The motive pressure of steam or air available to drive the pump. The selection of
steam or air will depend on the application and site circumstances.
The filling head available between the receiver and pump.
The total delivery head of the condensate system.
The method of sizing mechanical pumps varies from manufacturer to manufacturer, and
is usually based on empirical data, which are translated into factors and nomographs.
The following example gives a typical method for sizing a mechanical pump. (The pipe
length is less than 100 m consequently friction loss is ignored):

Example 14.4.3 How to size a mechanical condensate pump

Where:

Page 13 of 24

Fig. 14.4.9 Sizing a mechanical condensate recovery unit (see Example 14.4.3)

With reference to the sizing chart shown in Figure 14.4.10: a DN50 pump at 5.2 bar g
motive pressure will pump 2 600 kg/h against a 26 m head. A DN50 pump will
thus be an adequate choice for this example, where the condensate handling load is 2
100 kg/h.
Sizing the discharge pipework for a mechanical condensate pump
The discharge pipe from a mechanical pump can usually be taken to be the same size as
the pump outlet when it is below 100 m long. The frictional resistance of the pipe is
relatively small compared to the backpressure caused by the lift and condensate return
pressure, and can usually be disregarded. For discharge pipes longer than 100 m, the
general rule would be to select one pipe size larger than the pump outlet check valve,
but for such longer lines, the size should be checked as shown in Example 14.4.4
Delivery lines longer than 100 metres
On delivery lines over 100 m, and/or where the condensate flow is near the pump
capacity, it is advisable to check the pipe size to ensure that the total friction loss
(including inertia loss) does not exceed the pump's capability. Inertia loss is explained in
Example
14.4.4
Page 14 of 24

Consider the same condensate pumping requirement as in Example 14.4.3 but with a
line 250 meters long.
Example 14.4.4 Sizing a delivery line 250 m long (refer to Figure 14.4.10):
For a DN50 pump, with 5.2 bar g motive steam and 26 m delivery head, the maximum
pump capacity = 2600 kg/h.

Page 15 of 24

Fig. 14.4.10 Mechanical condensate recovery unit sizing chart - DN50 pump
The effect of inertia loss on pump delivery lines longer than 100 metres.
On lines over 100 m, a considerable volume of liquid will be held within the pump
discharge pipe. The sudden acceleration of this mass of liquid at the start of the pump
discharge can absorb some part of the pump energy and result in a large amount of
waterhammer and noise. This needs to be considered within the calculation by reducing
the allowable friction loss of 60 000 Pa in Example 14.4.4 by 50%, thus:
Page 16 of 24

Total allowable friction loss

With a frictional resistance of 109 Pa/m, Table 14.4.2 reveals that a 65 mm pipe
(minimum) is required to give an acceptable flowrate of 10400 kg/h. In fact, Table
14.4.2 indicates that a 65 mm pipe will pass 10620 kg/h with a frictional resistance of
109 Pa/m.
By rising up the '65 mm column' in the table, it can be seen that, by interpolation, the
flowrate of 10400 kg/h actually induces a frictional loss of 105 Pa/m in a 65 mm pipe.
Fully loaded pumps and longer lines
In Example 14.4.4, Figure 14.4.10 shows that the maximum pump filling rate with a
motive pressure of 5.2 bar g and a delivery head of 26 metres is 2600 kg /h. Had the
filling rate been close to this maximum, (perhaps 2 500 kg/h), then less delivery head
would have been available for friction loss. For the same size DN50 pump, this would
mean a larger delivery pipeline as shown in Example 14.4.5
Example 14.4.5 Consider the same DN50 pump as described in Example 14.4.4,
but having a condensate filling rate of 2 500 kg/h. Now determine the
size of the delivery pipeline.

Page 17 of 24

Fig. 14.4.11 Mechanical condensate recovery unit sizing chart (DN50 pump)
Sizing on a filling rate of 2 500 kg/h, and a steam pressure of 5.2 bar, referring to Figure
14.4.11, for the DN50 pump, it can be seen that a condensate filling rate of 2 500 kg/h
equates to a maximum backpressure of about 27 m, so in this instance:
With an actual delivery head of 26 m:
Page 18 of 24

The discharge pipework has to be sized on the instantaneous flowrate from the pump
outlet, which is taken as 4 x maximum pumping rate. As before the pipe would have
been sized on 4 x 2600 kg/h = 10400 kg/h with a friction loss of 18 Pa/m.

Table 14.4.2 shows that this would require a pipe diameter of 100 mm to allow the pump
to operate within its capability.
Although the system would certainly work with this arrangement, it is probably more
economical to consider a larger pump in conjunction with a smaller pipeline.
Considerations of a larger pump and smaller pipeline
Consider the same pumping conditions as Example 14.4.4, but with a larger DN80 pump.
As a larger unit can pump against a higher delivery head, a smaller delivery line can be
used.

Page 19 of 24

Page 20 of 24

Fig. 14.4.12 Mechanical condensate recovery unit sizing chart (DN80 pump)
Figure 14.4.12 shows that a DN80 pump under the same conditions of 5.2 bar g motive
steam and 2500 kg/h flowrate would allow a maximum delivery head of 35 m.

By interpolation, Table 14.4.2 shows that an 80 mm pipe will accommodate 20160 kg/h
with
a
friction
loss
of
160
Pa/m,
flowing
at
about
1
m/s.
In this instance, the larger DN80 pump will comfortably allow a pipe two sizes smaller
than that for the smaller pump, and with a velocity of about 0.5 m/s, which is within
recommendations. The 80 mm pipe is therefore suitable for the DN80 pump. In reality, a
65 mm pipe would be acceptable, since we have allowed for 50% inertia loss, however,
this
may
look
a
little
odd
connected
to
a
DN80
pump.
Note: The DN80 pump would cost about 10% more than the DN50 pump, but the extra
cost would be justified by the difference in installation costs on long delivery lines; which
in this instance would mean the difference in cost between a 80 mm and 125 mm pipe;
installation, fittings, and insulation.
Condensate velocities
Equation 14.4.2 can be used to check the condensate velocity.

Equation 14.4.2

In Equation 14.4.2, the specific volume of water is taken to be 0.001 m3/kg. This value
varies slightly with temperature but not enough to make any significant difference on
condensate
lines.
The condensate velocity can be checked for the 80 mm pipework in Example 14.4.4.

Page 21 of 24

From Table 14.4.3 the maximum velocity for an 80 mm bore pipe is 1.8 m/s.

Table 14.4.3 Maximum recommended velocities for pipe bores (based on a

maximum friction loss of 450 Pa/m)
Best practice for long delivery lines
The momentum of the moving contents of a long delivery line may keep the water in
motion for some time after a mechanical pump has completed its discharge stroke.
When the water in the discharge pipe comes to rest, the backpressure in the line will
attempt to reverse the initial flow of water, back towards the outlet check valve. The
result is noise and pipe movement due to water hammer, which can be both alarming
and serious. Installing another check valve in the discharge pipe one pipe length from
the pump will usually alleviate the problem.

Fig. 14.4.13 An additional check valve 1 pipe length from the pump body to
reduce the effect of backflow
If there is any choice, it is always best to lift immediately after the pump to a height
allowing a gravity fall to the end of the line (Figure 14.4.14). If the fall is enough to
overcome the frictional resistance of the pipe (Table 14.4.4), then the only backpressure
onto the pump is that formed by the initial lift. A vacuum breaker can be installed at the
top of the lift not only to assist the flow along the falling line but also to prevent any
tendency
for
backflow
at
the
end
of
the
stroke.
Should the falling line have to fall anywhere along its length to overcome an obstruction,
then an automatic air vent fitted at the highest point will reduce air locking and assist
flow around the obstruction, see Figure 14.4.14.
Page 22 of 24

Fig. 14.4.14 Best choice - lift after the pump

Table 14.4.4 Pipefall to overcome frictional losses

Alternatively, any question of backpressure caused by the horizontal run can be entirely
eliminated by an arrangement as in Figure 14.4.15 in which the pump simply lifts into a
vented break tank. The pipe from the tank should fall in accordance with Table 14.4.4.

Page 23 of 24

Fig. 14.4.15 Alternative choice - lift after the pump to a break tank
Vented pumps, pumping traps and pump-trap installations
Discharge lines from pumps vented to atmosphere are sized on the discharge rate of the
pump.
Condensate passing through pumping traps and pump-trap combinations in closed loop
applications will often be at higher pressures and temperatures and flash steam will be
formed
in
the
discharge
line.
Because of this, discharge lines from pumping traps and pump-trap combinations are
sized on the trapping condition at full-load and not the pumping condition, as the line
has to be sized to cater for flash steam. Sizing on flash steam will ensure the line is also
able to cope with the pumping condition.

Page 24 of 24