Condensate Systems – Design Sizing Operation & Optimization

What you'll learn
Discover how to effectively recover and reuse condensate to reduce energy costs and enhance system efficiency
Learn best practices for designing return lines to ensure safe, efficient, and smooth transport of condensate back to the boiler
Master the principles of calculating and sizing condensate return lines to prevent bottlenecks and pressure drops that could disrupt plant operations
Explore various methods of condensate removal from vented receivers, including mechanical pumping systems that optimize flow and energy use
Understand how to lift condensate over obstacles and into high-pressure zones with minimal energy loss and system strain
Requirements
The student who will gain the most from this course will come equipped with some knowledge of fluid flow and an acquaintance with steam systems. For these reasons, we strongly recommend that prior to taking the present course, you attend first our course
- Steam systems: Design, Sizing, Operation, Maintenance & Optimization
In addition, having taken our below training courses is a plus but not mandatory
- Designing Piping Systems: Pipe, Fittings, Flanges & Valves
- Valves & Control Valves: Principles, Operation & Design
- Heat Exchangers: Design, Operation & Maintenance
- Flow of Fluids Through Piping Systems, Valves, Fittings and Pumps
Description
In any process plant, steam and condensate systems are the backbone of efficient energy use. Without the proper recovery and management of condensate, valuable energy is wasted, system components deteriorate prematurely, and operational costs soar. This course will provide you with essential knowledge and tools to ensure your condensate systems are not just functional but optimized for peak performance.The course focuses on the following key areas:Condensate Recovery: Discover how to effectively recover and reuse condensate to reduce energy costs and enhance system efficiency.Layout of Condensate Return Lines: Learn best practices for designing return lines to ensure safe, efficient, and smooth transport of condensate back to the boiler.Sizing Condensate Return Lines: Master the principles of calculating and sizing condensate return lines to prevent bottlenecks and pressure drops that could disrupt plant operations.Pumping Condensate from Vented Receivers: Explore various methods of condensate removal from vented receivers, including mechanical pumping systems that optimize flow and energy use.Lifting Condensate: Understand how to lift condensate over obstacles and into high-pressure zones with minimal energy loss and system strain.This course is designed for engineers and plant operators who want to gain a deep understanding of condensate system design, operation, and maintenance. You'll be guided through step-by-step instructions, detailed technical descriptions, and engineering best practices, reinforced by extensive visuals, sizing tables, and real-world case studies.Key Features:Interactive quizzes and numerous solved problems to consolidate your learning.Comprehensive visual aids and graphics for a clearer understanding of complex concepts.Downloadable resources, including engineering data and design templates.By the end of this course, you will have the confidence to design, optimize, and troubleshoot condensate systems in a way that maximizes efficiency, safety, and reliability—ensuring your plant remains productive and cost-effective.Don't miss out on this opportunity to enhance your technical expertise! Enroll now to take your understanding of condensate systems to the next level.WR TrainingSpread the wings of your knowledge
Overview
Section 1: Condensate recovery
Lecture 1 Introduction to condensate recovery
Lecture 2 Calculating the amount of flash steam from condensate
Lecture 3 Live steam / Flash steam
Lecture 4 Why return condensate and reuse it ?
Lecture 5 The financial value or returning condensate
Lecture 6 Before you proceed to the next section
Section 2: Layout of condensate return lines
Lecture 7 Introduction to layout of condensate return lines
Lecture 8 Drain lines to steam traps (1/3)
Lecture 9 Sizing a drain line to a thermostatic trap
Lecture 10 Drain lines to steam traps (2/3)
Lecture 11 Drain lines to steam traps (3/3)
Lecture 12 Discharge lines from traps
Lecture 13 Common return lines
Lecture 14 Draining into flooded lines
Lecture 15 Discharge lines at different pressures
Lecture 16 Before you proceed to the next section
Section 3: Sizing condensate return lines
Lecture 17 Introduction
Lecture 18 Sizing drain lines to traps
Lecture 19 Sizing drain lines to traps - Worked example
Lecture 20 Sizing discharge lines from traps
Lecture 21 Factors affecting the two-phase flow
Lecture 22 Condensate pipe sizing chart
Lecture 23 Sizing for falling discharge lines - Worked example
Lecture 24 Sizing for rising discharge lines - Worked example
Lecture 25 Sizing for vented discharge lines - Worked example
Lecture 26 Common return lines - Falling lines
Lecture 27 Common return lines - Rising lines
Lecture 28 Falling common line - Apply your knowledge
Lecture 29 Rising common line - Apply your knowledge
Lecture 30 Before you proceed to the next section
Section 4: Pumping condensate from vented receivers
Lecture 31 Introduction to pumping condensate from vented receivers
Lecture 32 Pumping terminology
Lecture 33 Cavitation in centrifugal pumps experiment
Lecture 34 Head exercise with a positive displacement pump
Lecture 35 Centrifugal condensate pumps
Lecture 36 Sizing a condensate recovery unit
Lecture 37 Sizing the discharge pipe for a condensate recovery unit
Lecture 38 Positive displacement condensate pumps
Lecture 39 More on positive displacement condensate pumps
Lecture 40 Pump application
Lecture 41 Sizing a mechanical condensate pump
Lecture 42 Condensate pump sizing exercise
Lecture 43 Sizing the discharge pipe for a mechanical condensate pump
Lecture 44 Sizing the discharge pipe for a mechanical condensate pump - Worked example
Lecture 45 Sizing the discharge pipe for a mechanical condensate pump - Worked example 2
Lecture 46 Assessing a larger pump and a smaller delivery line
Lecture 47 Condensate velocities
Lecture 48 Best practices for long delivery lines
Lecture 49 Before you proceed to the next section
Section 5: Lifting condensate
Lecture 50 Lifting condensate from a steam main
Lecture 51 Contaminated condensate
Lecture 52 Before you proceed to the next section
Section 6: More on condensate system equipment - Steam traps
Lecture 53 Overview of steam traps
Lecture 54 Float traps
Lecture 55 Thermostatic traps
Lecture 56 Thermodynamic traps
Lecture 57 Inverted bucket traps
Lecture 58 Testing of steam traps
Lecture 59 Maintenance of steam traps
Lecture 60 Energy losses in steam traps
Lecture 61 Before you proceed to the next section
Section 7: More on condensate system equipment - Strainers
Lecture 62 Overview of strainers
Lecture 63 Wye strainers
Lecture 64 Basket strainers
Lecture 65 Strainer screens
Section 8: Downloadable resources
Lecture 66 Download me
This course is ideal for a wide range of professionals looking to deepen their understanding of condensate recovery. You will find the course content valuable if you are:,Engineers and Technicians working in process plants, power generation, petrochemicals, or any industrial sector that relies on steam systems for energy and production,Plant Managers and Operators responsible for the operation, maintenance, and optimization of steam and condensate systems and looking to improve plant efficiency and reduce operational costs,Maintenance Personnel tasked with troubleshooting and maintaining condensate systems, ensuring their reliable and safe operation,Energy Efficiency Specialists focused on maximizing energy recovery and minimizing waste through effective condensate recovery and optimization,New Engineers or Graduates looking to build a strong foundation in steam and condensate systems, preparing for a career in industries like refining, chemical processing, or power generation,Anyone Seeking Practical Knowledge in steam and condensate systems, even without prior experience, to boost their technical skills and understanding of industrial energy systems,Whether you're a beginner aiming to grasp the fundamentals or an experienced professional seeking advanced insights, this course offers valuable knowledge and real-world applications that will elevate your skills and enhance your career
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