A condensate return pump collects and redirects condensate produced by heating, ventilation or air conditioning (HVAC) equipment. It promotes more efficient condensate reuse by returning hot condensate to the boiler. With the right condensate return pump, your facility can reduce energy consumption, improve cost savings and enhance HVAC system performance.
There is no one-size-fits-all solution for choosing a steam condensate return pump. You will need to consider many factors to ensure you select the best pump for your specific needs and application. Here are the top nine factors to keep in mind when searching out a new condensate return pump.
1. Discover the System's Requirements
Before you start looking into your options, assess your existing system to determine your needs. Consider points such as:
- Pump capacity: Your pump should be capable of handling maximum condensate return flow with room to spare, ensuring the system can operate without reaching its limit.
- Condensate return rate: Since condensate is returned at varying rates from when it's produced, you'll want to find a pump that can effectively manage peak loads.
- Temperature: Your pump should be able to handle your condensate's range of thermal conditions without experiencing excess wear.
- Pressure: Look for a pump that can exert enough pressure to move condensate through the system efficiently.
- Chemical composition: Pump material should be able to handle your condensate's chemical composition to prevent corrosion and degradation.
- Noise level: If noise control is essential for your system, find information about pump noise levels during operation. Reading customer reviews and testimonials can give you more details about a pump's sound.
2. Learn About Your System's Flow Rate
Most manufacturers size condensate return pumps at three times the normal condensing or evaporation rate to quickly return the condensate to the boiler. Pumps should have a flow rate that can accommodate condensate and flash steam volume at the same time.
Choosing the right size for your condensate return pump ensures the ideal flow rate for your application, which enables you to prevent cavitation, damage and potential failure. Proper flow rate is also critical to maintaining the ideal temperature and pressure for optimal system performance.
3. Determine the Lift Requirement
Consider where your pump will be mounted and where the discharge point will be. How much vertical distance will your pump need to overcome to lift the condensate? The condensate flow rate will decrease the higher it travels, so you'll want to look for a pump that has a maximum lift or head rating that suits your application.
As lift requirement increases, it has the potential to cause insufficient net positive suction head (NPSH). Adequate NPSH is required to prevent cavitation, so be sure your new pump exceeds NPSH requirements at any given lift.
4. Calculate Differential Pressure
Your condensate return pump system needs to overcome differential pressure to return condensate to the boiler or feedwater tank as efficiently as possible. Select a pump that can handle factors such as:
- Static head: The pump should be able to overcome the vertical lift, or elevation, from the pump to the discharge point.
- Friction loss: Your pump needs to handle the resistance and pressure loss that can come as condensate moves through pipes, valves and fittings.
- Backpressure: Condensate will face backpressure in the return line, so be sure to choose a pump that can work against the pressure.
5. Confirm Voltage
You'll want to choose a pump that works within your existing electrical infrastructure. The pump's motor requirements should match your available power supply to ensure safe operation and optimal performance. Higher capacity applications and larger systems will require more voltage.
Running your pump at its designated voltage level can reduce excess energy consumption and operational costs. Voltage also affects torque, so choosing a pump with the right voltage for your application ensures the pump can operate effectively when under load.
6. Check Receiver Size
When selecting a new condensate return pump, consider how the pump will interact with the rest of your system. Choose a pump size that's compatible with the condensate receiver tank size to avoid short cycling and cavitation.
The receiver should have proper gross storage capacity for your application, meaning it can accommodate one minute's worth of condensate with additional capacity. Appropriate receiver tank size is also important for retaining heat, which can improve efficiency and energy savings.
7. Plan for Life Cycle Costs
To identify the best deal, compare upfront costs with the pump's expected performance, efficiency and longevity. Additionally, evaluate the total cost of ownership, including energy consumption, operating costs, maintenance and potential downtime needs. Depending on your location, you may also need to consider permitting and inspection costs when installing a new pump.
Investing in a high-quality pump can lead to cost savings with reduced maintenance and downtime requirements. The better your condensate return pump functions, the better the entire system will operate.
8. Think About Safety Features
As you browse pumps, search for options that offer the safety features you need, such as an overflow safety shut off or pressure relief valves. Emergency safety features can protect your equipment and the rest of the system against malfunctions and damage.
Find a pump that can handle mechanical and electrical failures. Consider automated shut-off processes and accessible manual shut-off switches as needed. You can further enhance safety by offering operator training.
9. Consider Regulations and Building Codes
Various regulations and building codes provide guidelines for condensate management, including how to choose the right condensate pump size. Always check local building codes before selecting a pump model, and be sure to review regulations from organizations such as:
- The American Society of Mechanical Engineers (ASME) and the Boiler and Pressure Vessel Code (BPVC)
- The National Fire Protection Association (NFPA) and the NFPA 90a
- The International Plumbing Code
Rules promote proper piping and drainage, which can minimize environmental impact and reduce nuisances and hazards. Adhering to these regulations and codes ensures your system is safe and efficient.
Find the Right Condensate Return Pump for Your Facility
ePumps is your one-stop solution for condensate systems. We offer a wide selection of Grundfos pressure pumps that can serve as a reliable condensate return pump for your specific application. Our team will work with you to discuss your needs and determine which pump will work best for you.
Browse our condensate return pump inventory and click on a product to learn more about its specifications. Want to learn more about condensate pumps and get advice about which product to choose? Our friendly customer service team is available 24/7 to assist.
