Condensate Recovery Pump Systems

Energy award-winning
flagship product

We sell Savings
 Steamline Condensate Recovery Pump Systems
Technical Data sheet

WINNER
DSK ENERGY AWARD

Celebrating
12 years of service
to the
Indian Process
Industry

We sell Savings

WHY RECOVER CONDENSATE?
Condensate is steam that has condensed as a result of doing
work and liberating heat. Being condensed water vapour
(steam) and relatively pure compared to most water supplies,
condensate is an excellent source of feedwater. Since
condensate is typically of better quality than normal make-up
sources, boiler water cycles of concentration can be increased
and blowdown amounts can be reduced with its use. This
results in a reduction of heat lost through blowdown, which
reduces the amount of heat (fuel) required to maintain operating
pressures.
The most important aspect of condensate is its heat content.
Feed water supplied at 95-100C needs less energy to go to an
operating pressure of 10 barg and temperature of 180C inside
the boiler. Ambient water supplied at 30C will use more heat,
ie, more fuel as shown in the figure below.
Temp
10 barg
Water at
100C Steam
180C
Water at
100C
Water at This is the heat saved by
30C recovering condensate
Heat
OPERATING PRINCIPLE
1 Filling Mode: Condensate fills by gravity flow into the pump.
The steam inlet is closed, exhaust is open, so no back pressure
is seen by the condensate entering the pump. As condensate
fills, the float rises towards the H position.
2 Transition to Pump Mode: As the float reaches position H,
the controller opens the steam inlet and closes the exhaust.
Steam rushes in, pressurising the pump to the steam pressure.
This pushes the water in the pump. The water cannot flow back
from the inlet (due to the NRV); it gets pushed out (or pumped)
through the condensate outlet.
3 Pump Mode: Condensate is pumped to the feedwater tank.
As the condensate level in the pump falls, the float descends
towards position L. Note that the steam is not used up to pump
the water - only the pressure exerted by the steam is used as a
motive force. Hence, the steam used is very little. The volume
of water between H and L is a constant and is used to totalise
the quantity of condensate returned.
4 Transition to Filling Mode: As soon as the float reaches
position L, the controller closes the steam inlet valve, and
opens the exhaust valve, as seen in figure m. The small
quantity of steam in the pump is exhausted, and the pump body
returns to atmospheric pressure. As soon as this happens, the
positive gravity head enables the condensate to start filling into
the pump, and the cycle repeats.
FEATURES OF STEAMLINE
CONDENSATE RECOVERY PUMP SYSTEMS
Steamline Condensate Recovery Pump Systems
Technical Data sheet
Finally, as condensate is water that a plant has already treated
(pre-treatment, scale/corrosion inhibitors, oxygen removed,
pumped and evaporated to steam i.e. distilled), it represents a
valuable investment that can be utilised over, if recovered.
Therefore, recovering and reusing condensate whenever
possible, is good energy management.
HOW IS IT DONE?
Condensate is discharged from steam using equipment through
steam traps. The condensate will be at the saturation
temperature corresponding to steam (and condensate)
pressure. However, this pressure is not always enough to lift the
condensate back to the boiler feed tank. Further, if multiple
traps discharge to a common line, a fluctuating back pressure
can cause malfunction of some of the traps. So the common
practice is to collect condensate in a tank and pump it back to
the boiler house.
Conventionally, an electrical pump is used, but this has many
special requirements - the pump needs to be switched On and
Off based on the water level in the condensate collection tank,
which radiates heat to the atmosphere. The high temperartures
of condensate cause cavitation in the pumps. The pump also
needs protection from dry running, and has many moving parts
such as bearings, impellers, bushings etc. which have their own
maintenance needs. Most of all, it uses expensive electricity,
taking away from the economic benefit of condensate return.
All these issues can be resolved by a Steamline Condensate
Recovery Pump System, a mechanical pump.
Controller Exhaust Exhaust
(open) (closed)
Steam inlet Steam inlet
(closed) (open)
H H
Condensate in
Condensate in
L L
NRV NRV
Exhaust Exhaust
(closed) (open)
Steam inlet Steam inlet
(open) (closed)
H H
Condensate in
To Feedtank
L L
4Uses inexpensive steam, air or gas to work
4Supplied complete with receiver, valves, accessories
4Negligible steam consumption
4Zero Maintenance, no cavitation, leaking seals, impeller
wear or motor problems
4Only one moving part (SS float) increases reliability
4Superior build quality and rugged construction
4Pre-wired, pre-piped package for easy installation
4Electronic Condensate flow totaliser included
4Widest range of steam-operated pumps in the market
 Steamline Condensate Recovery Pump Systems
Technical Data sheet

SIZING AND SELECTION

The Steamline CRPS is selected based on the following:

The motive pressure of steam available

The condensate load, given or calculated
Back pressure at the outlet against which the pump has to lift

Out of all the above parameters, for selection purposes we only

need to calculate the back pressure against which our pump
has to lift condensate.

UNDERSTANDING BACK PRESSURE

The condensate pump has to pump against a back pressure at Total Back pressure = (PV + PH + PFWT)
the outlet. This is the sum of vertical head, frictional losses
through the pipes and existing back pressures, if any. Where,
PV = pressure because of vertical head of water
= (0.1 X height in metres) barg
PH = frictional losses in horizontal travel
= (loss of 0.003 barg/m of horizontal travel)
For horizontal travel, we calculate the total length of pipe, and
PH then add 10% to this for valves and fittings online, to get an
Horiz. Travel in metres equivalent length of pipe,
(not as crow flies but actual PFWT ie, Eq. L = Horizontal length X 1.1
length)
PFWT = pressure if any in the boiler feed water tank
(0 if tank is atmospheric or typically 0.2-0.3 barg for a
Condensate Feed Water Tank pressurized line /tank /deaerator )
Receiver
PM = Motive pressure of steam or air

PV Vertical Lift in The motive force of steam/air (PM) must overcome this back
PM
metres pressure and lift the condensate to the boiler feed-tank.
PM - (PV + PH + PFWT) > 0.5 barg

EXAMPLE. If the motive pressure is not supplied by steam, but a pressurized

Let us take an example to illustrate sizing. air / gas, then the capacity of the pump increases by a factor as
1. Motive steam available = Steam at 5 bar g (PM ) shown below:
2. Condensate load = 1500 kg/hr
3. Vertical lift required = 15 m
4. Horizontal travel = 150 m % Back Capacity
5. Feedwater tank is pressurized at 0.5 bar g press. vs. multiplying
Capacity multiplying factors Motive press. factor
First, we calculate total back pressure. for motive air/gas
20% 1.04
PV = (15 X 0.1) = 1.5 barg
PH = 0.003 X (150 X 1.1) = 0.495 barg = 0.5 barg 40% 1.08
PFWT= 0.5 bar g (given) 60% 1.15
70% 1.20
So, Total Back pressure (PV+PH+PFWT) = (1.5+0.5+0.5)= 2.5 barg
Now, select the correct pump for these parameters from the
selection table below. On the left, go down to a Motive steam
pressure of 5 barg, choose the correct back pressure - 2.5 barg
and look for a condensate load of 1500 kg/hr.

From the selection table below, we can see that CRPS40 is the
best pump for our needs.
Selection Table

Max. Capacity in kg/hr

Motive
Steam Total Back
Pressure Pressure CRPS15 CRPS25 CRPS40 CRPS50 CRPS80 CRPS90 CRPS100 CRPS120 CRPS150
(in barg) (in barg)

0.5 500 910 1715 2525 4315 6040 9800 10890 12250
1.5
1.0 466 850 1405 2240 3865 5400 7500 8330 9375
1.5 556 1015 1625 2500 4245 5950 12015 13350 15018
3.5
2.5 471 860 1405 2105 3655 5120 9895 10994 12368
1.5 600 1095 1825 2700 4485 6280 12396 13773 15495
5
2.5 575 1050 1695 2475 4275 5985 9691 10767 12113
 Steamline Condensate Recovery Pump Systems
Technical Data sheet

MECHANICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS

Operating Parameters Inputs

Design Pressure 10 kg/cm2 g Instrument Air supply @ 4-6 kg/cmg
Design Temperature 180C Motive steam / Air Pressure @ 2-7 kg/cmg
Capacity Range 500 kg/hr
6 -digit Condensate Flow Totaliser Power
240 VAC, 50/60 Hz, 1A
Protection Class Fuse: 1.0 ampere, 5 x 20 mm
Flow Totaliser Protection rating IP 20
Solenoid Valves Protection rating IP 65
Controller Protection rating IP 65
Probe enclosure Protection rating IP 65
Control Card Enclosure Poly-carbonate
Cast Al w-proof to IP 65 or Ex-proof to Gr IIA, IIB or IIC
Ambient Temperature 0 to 50C

Materials
S.No. Part Material
1 Pump Body Fabricated steel IS3589
2 Receiver Fabricated steel IS3589
3 Piping MS IS1239
4 Flanges CS to ASTM A 105
5 NRVs Wafer Type SS 316
6 Float Assly SS 304
7 Probe enclosure Cast Aluminium
8 On - off Valve SS 304
9 Steam Inlet Valve SS 105
10 Controller Polycarbonate

$aving$
Saving in fuel as feed water temperature is increased
(6C rise = 1% increase in boiler efficiency)
Saving in fuel as blowdown loss is reduced Besides hydrotests and
Saving of water treatment chemicals and processes pneumatic tests, each and
every Steamline CRPS is
Saving of the water itself
functionally tested in the
Saving in Power when replacing electrical pump factory for 72 hours on our
By recovering condensate you also reduce load on unique test-rig before being
effluent plant and effluent treatment cost shipped to you.
 Steamline Condensate Recovery Pump Systems
Technical Data sheet

SCHEMATIC DRAWING CRPS 15/ 25/ 40/ 50/ 80/ 90

Cond Inlets Receiver to Condensate Steam Steam Vent Overflow (BSP)

to Receiver Pump Inlet Pump Outlet Inlet Exhaust
A B C D E F G
CRPS 15 2 X 25NB 25NB 15NB 15NB 15NB 25NB 15NB
CRPS 25 2 X 50NB 25NB 25NB 15NB 15NB 25NB 25NB
CRPS 40 2 X 50NB 40NB 50NB 15NB 15NB 50NB 25NB
CRPS 50 2 X 50NB 50NB 50NB 15NB 15NB 50NB 25NB
CRPS 80 2 X 50NB 80NB 50NB 15NB 15NB 50NB 25NB
CRPS 90 2 X 50NB 100NB 80NB 25NB 25NB 50NB 25NB

900mm 450mm

A A F G
Overflow

FRONT VIEW SIDE VIEW

Receiver

Controller Flow
Totaliser

Valve
E
1680mm

Strainer

Pump Body

B C

Condensate Condensate
Inlet Outlet
 Steamline Condensate Recovery Pump Systems
Technical Data sheet

SCHEMATIC DRAWING CRPS 100/ 120/ 150

Cond Inlets Receiver to Condensate Steam Steam Vent Overflow (BSP)

to Receiver Pump Inlet Pump Outlet Inlet Exhaust
A B C D E F G
CRPS 100 1 X 100NB 100NB 100NB 25NB 40NB 50NB 50NB
CRPS 120 1 X 150NB 150NB 100NB 40NB 50NB 50NB 50NB
CRPS 150 1 X 150NB 150NB 150NB 40NB 50NB 50NB 50NB

1260

A F G
Over Flow

FRONT VIEW
Receiver

Butterfly Drain
Valve

Controller Flow
Totaliser

2150
Steam Inlet D

Strainer
E Exhaust

Pump Body

B
C
NRV Drain
NRV

In the interest of continuous product development, Steamline

reserves the right to upgrade or modify any specifications without
prior notice. For the latest revision, please refer to our website
www.steamline.com or contact your local Steamline Sales Engineer.
Steamline, 1999-2011. All rights reserved.
Condensate Recovery Pump Systems
Partial Reference List
Sr. Client & Location Qty Sr. Client & Location Qty

1 Deepak Spinners, Chandigarh 1 61 Praj Industries Ltd, Pune 1

2 Leela Dye House, Chandigarh 1 62 Godfrey Phillips, Mumbai 1
3 Weikfield Agro, Pune 1 63 Energy Avenues, Mohali 1
4 Tulsi Rubber, Pune 1 64 Energy Avenues, Mohali 1
5 Parakh Foods, Pune 2 65 Energy Avenues, Mohali 1
6 Cadbury India, Pune 2 66 Precision Controls, Pune 1
7 Wimco, Mumbai 1 67 Energy Avenues, Mohali 1
8 Dynamix Dairy, Pune 5 68 Energy Avenues, Mohali 1
9 Cadbury India, Pune 1 69 Cee Dee Vaccum, Pune 1
10 Lona Industries, Patalganga 5 70 Global Oils & Fats Ltd, Pune 1
11 Shriram Trading & Mfg Co, Kolhapur 1 71 Energy Avenues, Mohali 1
12 Lona Industries, Patalganga 1 72 Energy Avenues, Mohali 1
13 Fresenius Kabi, Pune 1 73 Deepak Fertilisers, Pune 2
14 Orchid Chemicals, Aurangabad 1 74 Precision Controls, Pune 1
15 Sudarshan Chemicals, Roha 1 75 Alok Industries, Vapi 5
16 Fresenius Kabi, Pune 1 76 Energy Avenues, Mohali 2
17 Fresenius Kabi, Pune 2 77 Multi Organics, Chandrapur 1
18 Dynamic Systems, Kolhapur 1 78 Energy Avenues, Mohali 2
19 Vilson Particle Board, Kolhapur 1 79 Energy Avenues, Mohali 4
20 Privi Aromatic, Mahad 1 80 Precision Controls, Pune 2
21 Orchid Chemicals, Aurangabad 1 81 Alok Industries, Vapi 1
22 Cadbury, Malanpur MP 1 82 Precision Controls, Pune 2
23 Fresenius Kabi, Pune 1 83 Energy Avenues, Mohali 2
24 Tata ACSI, Pune 1 84 Suvarna Fibrotech, Pune 1
25 Global Oils and Fats Ltd, Gujarat 5 85 Serum Institute, Pune 3
26 Thermax Chemicals, Khopoli 3 86 Serum Institute, Pune 1
27 Intervet, Wagholi 1 87 Serum Institute, Pune 1
28 SRF Limited, Malanpur 1 88 Vijay Engineers, Pune 1
29 Thermax Microlabs, Chinchwad 4 89 Alok Industries, Vapi 5
30 Core Industrial Marketing, Chandigarh 2 90 ATC Tires, Tirunelveli 2
31 Sudarshan Chemicals, Roha 1 91 North East Pure Drinks, Guwahati 2
32 Aggarwal Rice Mills, Moga 1 92 Croda Chemicals (I) Pvt Ltd, Mumbai 1
34 Hamdule Brothers, Pune 1 93 Energy Avenues, Mohali 5
35 Energy Avenues, Mohali 1 94 Varun Beverages Nepal Pvt Ltd, Nepal 2
36 Godfrey Phillips, Mumbai 1 95 Energy Avenues, Mohali 1
37 Godfrey Phillips, Mumbai 1 96 Atlas Fine Chemicals, Nasik 1
38 Lona Industries, Patalganga 1 97 Kamani Oil Ind Pvt Ltd, Khopoli 3
39 JK Industries, Kankroli 1 98 Precision Controls, Pune 1
40 Baxter India, Waluj 3 99 Zytex Biotech Pvt Ltd, Mumbai 1
41 Energy Avenues, Mohali 3 100 Precision Controls, Pune 3
42 Tata ACSI, Pune 1 101 Cipla Limited, Kurkumbh 1
43 Core Industrial Marketing, Chandigarh 1 102 Cargill India Pvt Ltd, Kutch 1
44 Cipla Limited, Kurkumbh 1 103 Sudarshan Chemicals, Roha 3
45 Tata ACSI, Pune 1 104 Kamani Oil Ind Pvt Ltd, Khopoli 1
46 Regent Drugs, Gajraula 1 105 Meghmani Organics, Panoli 1
47 Energy Avenues, Mohali 2 106 Meghmani Organics, Ahmedabad 1
48 Cee Dee Vaccum, Pune 1 107 Cipla Limited, Patalganga 1
49 Privi Organics, Mahad 1 108 Alok Industries, Vapi 2
50 Pratima Enterprises, Pune 1 109 Mayur Dye Chem, Baroda 1
51 Tata ACSI, Uttaranchal 1 111 KP Engineering Co, Pune 1
52 Energy Avenues, Mohali 2 112 Oswal Denims, Punjab 1
53 Regent Drugs Ltd, Gajraula 1 113 Oswal Denims, Punjab 1
54 Orchid Chemicals, Aurangabad 1 114 Precision Controls, Pune 1
55 Orchid Chemicals, Aurangabad 1 115 Kores India Limited, Roha 1
56 Orchid Chemicals, Aurangabad 1 116 Sudarshan Chemicals, Mahad 2
57 Themis Medicare Limited, Vapi 1
58 Tata ACSI, Pune 1
59 Shalina Laboratories, Mumbai 2
60 Energy Avenues, Mohali 1

Head Office and Works:

S. No. 32/3/14, Kondhwa Budruk, Pune, Maharashtra, India 411 048.
Phone: + 91 20 2693 2213 Fax: + 91 20 2693 2214
Email: sales@steamline.com Web: www.steamline.com