CONDENSATE EXTRACTION PUMP

CHAPTER 1
Introduction
1.1 Pump
A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by mechanical
action. Pumps can be classified into three major groups according to the method they use to
move the fluid: direct lift, displacement, and gravity pumps.
A pump is a machine that imparts energy into a liquid to lift the liquid to a higher level, to
transport the liquid from one place to another, to pressurize the liquid for some useful purpose,
or to circulate the liquid in a piping system by overcoming the frictional resistance of the piping
system. The pump is one of the oldest machines invented by man. The earliest pumps devised for
raising water, such as the Persian and Roman waterwheels and the more advanced Archimedean
screw, were invented to raise water from the hold of a ship. Since that time, many variations and
applications of pumps have been developed, which in most cases can be classified into two basic
methods used to impart energy to a liquid: volumetric or positive displacement, and addition of
kinetic energy. Volumetric (positive) displacement of a fluid can be accomplished either
mechanically by the action of a screw or a plunger, or by the use of another fluid. Kinetic energy
can be added to a fluid by rotating the fluid at high speeds, in a device typically known as a
centrifugal pump, or by providing an impulse in the direction of flow.

1.2 Condensate Extraction Pump

Condensate extraction pumps are medium flow medium-head pumps that pump condensate
from the condenser hot well generally through a series of low-pressure feedwater heaters to a
deaerating heater. These pumps operate at a very low pressure at their suction with cold
condensate, which can lead to pump damage because of cavitation if the pumps are not carefully
selected to allow for these severe operating conditions. Both horizontal and vertical condensate
pumps can be used. Years ago, typical condensate pumps used in central power stations were
horizontal multistage centrifugal pumps because of their ease of installation, maintainability,
availability, reliability, and operability. However, with the trend toward larger power stations,
larger condensers, and lowered hot wells to reduce building costs, the NPSH available to the
condensate pumps, already low, was reduced considerably more. As a result, the horizontal
centrifugal condensate pumps have been replaced with vertical, multistage pumps, mounted in
suction "cans" beneath the plant ground floor. The suction "can" lengths are determined so that

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adequate NPSH is provided to the centerline of the first-stage impeller for proper operation of
the condensate pump.

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CHAPTER 2
Construction and Operation
Condensate pumps as used in hydronic ( is the use of a liquid heat-transfer medium in heating
and cooling systems) systems are usually electrically powered centrifugal pumps. As used in
homes and individual heat exchangers, they are often small and rated at a fraction of a
horsepower, but in commercial applications they range in size up to many horsepower and the
electric motor is usually separated from the pump body by some form of mechanical coupling.
Large industrial pumps may also serve as the feedwater pump for returning the condensate under
pressure to a boiler.
Condensate pumps usually run intermittently and have a tank in which condensate can
accumulate. Eventually, the accumulating liquid raises a float switch energizing the pump. The
pump then runs until the level of liquid in the tank is substantially lowered. Some pumps contain
a two-stage switch. As liquid rises to the trigger point of the first stage, the pump is activated. If
the liquid continues to rise (perhaps because the pump has failed or its discharge is blocked), the
second stage will be triggered. This stage may switch off the HVAC equipment (preventing the
production of further condensate), trigger an alarm, or both.

Some systems may include two pumps to service the tank. In this case, the two pumps often
alternate operation, and a two-stage switch serves to energize the on-duty pump at the first stage
and then energize the remaining pump at the second stage. This second stage action is in addition
to any triggering of other system changes as noted for a single pump installation. In this way

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pump runtime is shared between the two, and a backup pump is provided in case one pump fails
to function as designed.

Steam condensate pump

Small pumps have tanks that range from 2 to 4 litres (0.5 to 1 gallon) and are usually supported
using the flanges on their tanks or simply placed upon the floor. A plastic impeller in a molded
volute at the bottom of the pump provides the pumping action; this impeller is connected to the
motor via a metal shaft that extends downwards from the motor mounted above the tank's top.
Large pumps are usually pad-mounted drawing liquid from a tank (sump) below the floor. The
smallest pumps may have no tank at all and are simply placed within a container such as the drip
pan of a dehumidifier appliance. In industrial steam systems the condensate pump is used to
collect and return condensate from remote areas of the plant. The steam produced in the boiler
can heat equipment and processes a considerable distance away. Once steam is used it turns to
hot water or condensate. This pump and possibly many more around the plant returns this hot
water back to a make-up tank closer to the boiler, where it can be reclaimed, chemically treated,

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and reused, in the boiler, consequently it can sometimes be referred to as a condensate return
pump.
In a steam power plant, particularly shipboard ones, the condensate pump is normally located
adjacent to the main condenser hotwell often directly below it. This pump sends the water to a
make-up tank closer to the steam generator or boiler. If the tank is also designed to remove
dissolved oxygen from the condensate, it is known as a Deareating feed tank (DFT). The output
of the DFT supplies the feed booster pump which, in turn, supplies the feed pump (feedwater
pump) which returns the feedwater to the boiler so the cycle can start over. Two pumps in
succession are used to provide sufficient Net Positive Suction Head to prevent cavitation and the
subsequent damage associated with it.
This pump is usually associated with a much larger tank, float switch, and an electric motor than
the example above. Some systems are so remote that steam power is used to return the
condensate where electricity is impractical to provide.

2.1 Casing
It is split on right to the shaft and consists of suction rings and 4 no. of guide vane housing.
Casing components are bolted together and sealed off from one another by 'O' rings. For internal
sealing of individual stages, the casing components are provided with exchangeable casing wear
rings in the arc of impeller necks. In each guide vane casing, a bearing bush is installed to guide
the shaft of pump

2.2 Rotor
The pump impellers are radially fixed on the shaft by keys. The impellers are fixed in position
axially by the bearing sleeves and are attached to the shaft by means of impeller nut. Impellers
are single entry type, semi-axial and hydraulically balanced by means of balance holes in the
shroud and throttle sections at suction and discharge side. A thrust bearing located in the motor
stool absorbs residual axial thrusts.

2.3 Bearings
In each guide vane housing the shaft is guided by a plain bearing. These bearings do not absorb
any axial forces. Pump bearings consist of bearing sleeve, rotating with the shaft and bearing
bush, mounted in guide vane housing. The intermediate shaft is guided in bearing spider and
shaft sleeve. The arrangement of bearing corresponds to the bearings of pump shaft. They are

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lubricated by condensate itself. A combined thrust and radial bearing is installed as support
bearing to absorb residual thrust. Axial load is transmitted to the distributor casing via the thrust
bearing plate, the thrust bearing and bearing housing. A radial bearing attached to the bearing is
installed in an enclosed housing and is splash lubricated by oil filled in the enclosure. Built-in
cooling coils in the bath and cooling water control oil temp.

2.4 Shaft sealing

The drive shaft passage in the distributor casing is sealed off by packed stuffing box with lantern
ring. During operation, the packed stuffing box reduces the leakage flow in the clearance
between shaft protecting sleeve and stuffing box housing. The shaft protecting sleeve is sealed
off from shaft by 'O'rings. To prevent air entry during standstill operation or during reduced
pressure operation as well as for cooling stuffing box sealing water is fed into the stuffing box
via lantern ring. Connecting line to suction relieves the shaft-sealing chamber.

2.5 Coupling
The pump shaft coupling is connected to the driver shaft by a rigid clamp coupling. A flexible
claw coupling is used to transmit the torque from driver to drive shaft.

2.6 Venting/sealing/cooling fluid lines

A vent line connects the suction compartment to the top of suction vessel, with an isolating
valve. This is to vent the pump off any gas formation, which might interfere with smooth
running of pump. From the pressure relief line a partial flow is branched off as sealing fluid.

2.7 Condensate Pump Specifications.

The following suggested condensate pump requirements that affect the design, manufacturing,
and operation of a condensate pump should be included in any condensate pump procurement
specification. Pump Lubrication System, Motor bearings are grease lubricated. The pump
bearing is a thrust-cum-journal bearing sub-merged in an oil bath. The oil is cooled by clarified
water.

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2.8 Typical specification

2.8.1 Pump
Design Overload
Type WKTA 200/4
Speed 1480 rpm. 1480 rpm.
Discharge Capacity 610 m3/hr 710 m3/hr
Head 190m 170m
power 402KW 429KW
Temperature of medium Water at 40ºC
handled

2.8.2 Motor
Power : 470 KW
Supply : 6.6 KV, 3-phase, 50 Hz, PF=0.85 lag.

Current : 51 Amps.

Speed :1480 rpm.

Class of Insulation :F

2.9 PUMP TYPE AND ARRANGEMENT.

The specification should include the desired pump type, number of pumps required, location of
the pumps, and plant arrangement. For current power stations, the condensate pump installation
is typically a vertical, wet suction, multistage "can" type pump. These pumps are normally
located near the condenser hot well, at ground level, arranged for a below-floor suction from the
condenser hot well and for above-floor discharge.

2.10 SYSTEM DESIGN CONDITIONS.

The following design conditions should be provided to the pump manufacturer:
• Design capacity for each pump during parallel operation, at minimum condenser hot well level.

• Total developed head, based on the design capacity and low condenser hot well level.

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• Net positive suction head available, based on design capacity typically referred to the pump
support elevation and in accordance with the worst case condenser vacuum operating condition.
Plant arrangement and condensate pump setting must be considered.
• Condensate temperature, typically specified for both the design conditions and at maximum
required capability of the pump.
• Allowable shutoff head for both the maximum and minimum allowable.
• Maximum suction specific speed for the first-stage impeller. See previous discussions.
• Maximum pump speed, typically specified at 1,200 rpm or 1,800 rpm, depending on the pump fit
with hydraulic operating conditions included in the specification.
• Water chemistry, including the anticipated concentration of each constituent of the condensate,
including pH.

OPERATIONAL REQUIREMENTS.
The specification should include the single or parallel operation requirements and a description
of the type of flow control that will be designed into the condensate system (regulating valve or
variable speed operation). Requirements regarding how many pumps are included in parallel as
well as a short description of the anticipated startup/shutdown operation of the pumps should be
given. System head curves for single-pump operation and all parallel pump operating modes
should be provided.

MATERIALS OF CONSTRUCTION.
Materials of construction should be specified for each pump component. The pump material
included in the specification should be the minimum requirements based on the application with
the allowance that the pump manufacturer may suggest alternate materials that are equivalent to
or exceed the strength of corrosion erosion properties of the materials specified. Some typical
materials are presented in Table.

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Pump components Typical material selection

Suction can, column and discharge head Carbon steel, ASTM A36 or ASTM 283
Bowls Cast carbon steel, ASTM A216 Grade
WCB
Impellers 12-14% chromium stainless steel, ASTM
A743
Shaft 11.5-13.5% chromium stainless steel,
ASTM A276
Wearing rings 12-14% chromium stainless steel, ASTM
A582
Bearings Carbon or graphalloy
Bowl bolting 12% chromium stainless steel, ASTM
A193

Condensate pump selection

The two important condensate pump selection factors that remain are the number of condensate
pumps required and the type of pump flow control to be used.

condensate pump flow control

Constant-speed and variable-speed condensate pumps are the two types of flow control typically
used in modern power station installations.
A summary of the design features and operating characteristics of each type follows.

constant speed condensate pump with throttle valve control

This arrangement consists of condensate pumps connected directly to constant-speed motors.
Flow control is accomplished by control valves located downstream of the condensate pumps.
This type of arrangement is shown in Fig.

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fig system resistance curve, constant speed condensate pump with throttle valve.

The system resistance curve shown on this figure represents the sum of the deaerator pressure,
static head, and pressure losses due to the piping, valves, and equipment. The friction loss across
the control valve is shown as a separate item to aid in explaining one of the differences between
constant-speed and variable-speed pump operation. The design head that the pump must develop
at the design flow rate is the sum of the system resistance and the pressure drop through the
control valve at the design flow rate.

Variable speed condensate pump.

variable-speed pump drives for flow control do not require control valves. The design head for a
variable-speed pump is less than the design head for a constant-speed pump by the amount of
pressure loss across the control valve. Variable-speed condensate pumps can be driven by
variable speed motors, by constant-speed motors through variable speed couplings, or by
variable frequency drive arrangements. The effect of varying the pump speed on the pump head
curve is shown in Fig.

fig. system resistance curve variable-speed condensate pump.

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The variable-speed pumping arrangement generally has higher capital costs, but has lower
energy and demand costs. For a peaking unit, variable-speed condensate pumps would be very
attractive and provide the operator with additional operating flexibility.

Number of condensate pump

Typically, the number and size of condensate pumps is selected from the following arrangement:

• Two half-capacity pumps,

• Three half-capacity pumps, or
• Two full-capacity pumps.

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CHAPTER 3

CONDENSATE CYCLE

Condensate cycle consist of following units.

 condenser
 condensate polishing unit (CPU)
 Gland steam condenser
 Dry cooler
 Low pressure heaters (LPU)
 Deaeretor (D/A)

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