Process Integration and System Design

Medium-pressure condensate drums serve as intermediate collection points in staged separation systems, receiving condensate from MP steam trap networks, heat exchanger drains, process equipment jackets, and second-stage separators. The elevated operating pressure requires robust vessel design while creating opportunities for flash steam recovery to lower-pressure systems.

Proper sizing balances liquid retention requirements with vapor disengagement needs. Adequate residence time allows dissolved gases to evolve and separate, preventing downstream pump cavitation and process upsets. Surge capacity accommodates flow variations during process transitions, equipment cycling, or emergency shutdowns without overflow or system disruption.

Vessel orientation selection depends on site constraints and process requirements. Horizontal drums provide maximum liquid capacity and vapor disengagement area for high-flow applications. Vertical configurations minimize plot space requirements while offering superior separation efficiency through gravity-driven stratification.

Advanced Internal Design for Separation Efficiency

Medium-pressure operation demands carefully engineered internals to achieve optimal vapor-liquid separation. High-efficiency wire mesh demister pads capture entrained liquid droplets, achieving 99.5%+ removal efficiency for particles above 10 microns. Vane-pack mist eliminators handle higher liquid loadings in applications with significant flash gas generation.

Inlet cyclone separators or tangential entry devices provide preliminary liquid-gas separation, reducing demister loading and extending maintenance intervals. Distribution baffles prevent jet impingement and flow channeling that compromise separation performance. Impact plates protect internal components from erosion in high-velocity inlet streams.

Anti-vortex devices at liquid outlets prevent gas breakthrough during pump suction, maintaining NPSH requirements and protecting rotating equipment. Liquid level weirs or standpipes control retention time and interface positions in applications handling multiple liquid phases. Sloped bottoms or drain sumps ensure complete liquid removal during system maintenance.

Structural supports, stiffener rings, and internal bracing withstand operating pressures while supporting component weights and dynamic loads. Nozzle reinforcement pads distribute stress concentrations, with all pressure-containing welds receiving full radiographic examination per ASME requirements.

Manufacturing Standards and Material Selection

Fabricated to ASME Section VIII Division 1 with complete U-stamp certification, MP condensate drums undergo rigorous quality control including 100% radiographic examination of circumferential and longitudinal seams, hydrostatic testing at 1.3× design pressure, and comprehensive NDT per ASME Section V. Manufacturing at the 40,000 m² Mersin facility employs automated welding systems, precision machining centers, and dedicated testing areas for pressure vessels up to 300 bar capacity.

Material selection addresses operating conditions, condensate chemistry, and service life requirements. Carbon steel (SA-516 Grade 70) provides reliable service for standard hydrocarbon and steam condensate applications. Stainless steel grades (304, 316, 316L) resist corrosion from acidic condensate, chemical contaminants, or high-purity requirements.

For sour service or corrosive environments, NACE MR0175/ISO 15156 compliant materials ensure long-term integrity. Post-weld heat treatment relieves residual stresses in thick-wall vessels or low-alloy steel construction. Internal cladding or overlay welding protects base metal from localized corrosion while maintaining pressure boundary integrity.

All materials include certified mill test reports with chemical composition analysis and mechanical property verification. Positive material identification confirms specifications before fabrication begins. Welding procedures undergo qualification testing, with certified welders assigned to pressure-critical operations.

Comprehensive Instrumentation and Automation

Advanced instrumentation enables precise level control and system optimization. Guided-wave radar or non-contact ultrasonic transmitters provide accurate level measurement resistant to foam, turbulence, and changing fluid properties. Redundant level switches at critical points trigger pump operation, alarm functions, and emergency shutdown sequences.

Pressure transmitters monitor operating conditions with high-accuracy sensors and temperature compensation. Differential pressure measurement across demister pads indicates fouling conditions and maintenance requirements. Temperature instrumentation tracks condensate quality and identifies system upsets.

Control systems integrate with distributed control systems (DCS) or programmable logic controllers (PLC) through industry-standard protocols including Modbus, HART, and Foundation Fieldbus. Remote monitoring capabilities provide real-time visibility into vessel performance, with data logging supporting predictive maintenance and process optimization.

Automated level control maintains optimal drum inventory through pump speed modulation or on-off control sequences. Cascade control strategies coordinate multiple drum operations in complex process systems. Advanced control algorithms anticipate load changes and adjust pump operation to prevent level excursions.

Complete Turnkey System Supply

Integrated packages include all components required for operational readiness. The vessel body with complete internals arrives with factory-installed instrumentation, structural supports, and access provisions. Pump packages with 2×100% capacity configurations ensure reliability, featuring variable frequency drives for energy optimization and soft-start capabilities protecting electrical systems.

Piping assemblies include inlet and outlet connections, vent headers, drain systems, and instrument taps fabricated to ASME B31.1 or B31.3 standards. Control panels house electrical components, instrumentation signal conditioning, and operator interface systems in NEMA-rated enclosures suitable for industrial environments.

Skid-mounted configurations undergo complete factory testing including hydrostatic pressure testing, instrumentation calibration, and control system functional verification. Modular designs facilitate transportation and enable rapid field installation with minimal construction labor.

Heat tracing systems maintain condensate temperature in cold climates, preventing wax solidification or hydrate formation. Insulation packages minimize heat loss and protect personnel from hot surfaces. Weatherproof coatings protect external surfaces in corrosive atmospheres or outdoor installations.

Diverse Industrial Applications

Refinery Processing: Crude distillation condensate, fluid catalytic cracker condensate, and hydrotreating unit drains across multiple pressure stages

Petrochemical Operations: Ethylene plant quench tower condensate, propylene fractionation systems, and aromatics complex drainage networks

Power Generation: Extraction steam condensate in reheat cycles, boiler feedwater heater drains, and auxiliary steam system collection

Chemical Manufacturing: Multi-stage reactor condensate, distillation column overhead systems, and process heating circuit drainage

Oil & Gas Production: Well stream separation condensate, gas processing plant drainage, and field condensate stabilization systems

Technical Capabilities

• Design Standards: ASME Section VIII Division 1, API 521, ASME B31.1/B31.3
• Operating Pressures: 50 psig to 150 psig typical, higher ratings available
• Capacity Range: 200 gallons to 10,000+ gallons
• Materials: SA-516 Gr 70, SA-537 Class 2, SS 304/316/316L, NACE compliant alloys
• Temperature Range: 250°F to 400°F operating conditions
• Configurations: Horizontal or vertical, skid-mounted or field-erected
• Relief Protection: Sized per API 521, redundant devices for critical service
• Testing: Full hydrostatic testing, radiographic examination, PMI verification

Engineering Support and Project Execution

In-house engineering teams perform detailed process calculations including flash gas generation rates, separation efficiency modeling, and pump NPSH analysis. Computational fluid dynamics (CFD) simulations optimize internal configurations for complex applications. Finite element analysis (FEA) verifies structural adequacy under operating and upset conditions.

Design packages include complete P&IDs, general arrangement drawings, fabrication details, and installation specifications. 3D modeling coordinates interfaces with existing plant infrastructure and identifies potential installation challenges before construction begins.

Project management coordinates fabrication schedules, inspection hold points, and quality documentation requirements. Expediting services track material procurement and manufacturing progress, ensuring on-time delivery for project schedules.

Installation support includes construction supervision, welding inspection, and hydrostatic testing coordination. Commissioning assistance verifies system performance against design specifications. Operator training programs cover normal operation, troubleshooting procedures, and maintenance requirements.

Long-term support includes spare parts availability for instrumentation and mechanical components, periodic inspection services following API 510 guidelines, and technical consultation for process modifications or system upgrades. Performance monitoring identifies optimization opportunities and extends equipment life through predictive maintenance strategies.

MP condensate drums deliver reliable separation performance and condensate management through precision engineering, quality fabrication, and complete system integration tailored to medium-pressure industrial applications.