Engineered Design for Optimal Performance

Low-pressure condensate drums handle condensate from multiple sources including LP steam trap discharges, heat exchanger drains, final-stage separators, and turbine exhaust condensers. The reduced operating pressure creates favorable conditions for flash gas evolution, making proper vapor disengagement critical for downstream pump protection and process efficiency.

Vessel sizing accounts for liquid retention time, vapor disengagement space, and surge capacity to handle intermittent condensate flows during load changes or equipment startups. Horizontal configurations are common for high liquid volumes, while vertical designs suit space-constrained installations or applications requiring minimal liquid inventory.

Internal Components and Separation Technology

Effective vapor-liquid separation at low pressures requires carefully engineered internals. Wire mesh demister pads remove entrained liquid droplets from rising vapor streams, achieving 99%+ separation efficiency for droplets above 10 microns. Inlet distribution devices prevent turbulence and foam formation that could compromise separation performance.

Anti-vortex breakers at liquid outlet nozzles prevent gas entrainment into downstream pumping systems, protecting equipment from cavitation and ensuring reliable operation. Baffle plates manage flow distribution and provide structural support for internal components. Sloped bottoms or conical sections ensure complete drainage during maintenance or system shutdowns.

Level control systems maintain optimal liquid inventory, with high-level alarms preventing overflow and low-level protection safeguarding pump operation. Pressure relief devices protect against overpressure scenarios, while vacuum breakers prevent tank collapse during rapid liquid drawdown or cooling.

Manufacturing Excellence and Quality Standards

Manufactured to ASME Section VIII Division 1 standards with U-stamp certification, LP condensate drums feature full radiographic examination of critical welds, hydrostatic testing at 1.3× maximum allowable working pressure, and comprehensive material traceability. The 40,000 m² manufacturing facility in Mersin combines automated welding systems, CNC fabrication equipment, and in-house testing capabilities to ensure code compliance and superior quality.

Materials selection depends on condensate chemistry and operating temperature. Carbon steel (SA-516 Grade 70) provides economical construction for standard applications, while stainless steel grades (304, 316, 316L) address corrosive condensate conditions. Internal coatings or linings extend vessel life when chemical attack or contamination concerns exist.

All pressure-containing components including nozzles, flanges, and reinforcement pads meet ASME B16.5 specifications with full PMI testing. Complete documentation packages include design calculations, material certifications, welding procedures, NDT reports, and hydrostatic test records.

Integrated Instrumentation and Control Systems

Comprehensive instrumentation enables reliable operation and process optimization. Differential pressure or guided-wave radar level transmitters provide continuous level monitoring with 4-20mA output signals for DCS integration. Multiple level switches (low-low, low, high, high-high) trigger pump control sequences and alarm functions.

Pressure and temperature instrumentation monitors operating conditions, with data logging capabilities supporting performance analysis and troubleshooting. Sight glasses permit visual liquid level verification during commissioning and operation. Sample connections facilitate periodic condensate quality testing.

Automated pump control maintains optimal drum levels, with 2×100% capacity configurations ensuring continuous operation during maintenance. Variable frequency drives optimize pump performance across varying load conditions, reducing energy consumption and mechanical stress.

Complete System Integration

Beyond the vessel itself, complete packages include foundation supports, piping assemblies, instrumentation panels, and electrical integration. Skid-mounted configurations arrive factory-tested and ready for installation, minimizing field labor and construction schedules.

Vent connections route flash gases to flare systems, vapor recovery units, or low-pressure steam headers depending on gas composition and facility infrastructure. Heat tracing and insulation maintain operating temperatures in cold climates, preventing wax formation or hydrate plugging.

Structural platforms, ladders, and access provisions enable safe inspection and maintenance. Lifting lugs facilitate vessel handling during installation, while anchor bolt chairs ensure proper foundation attachment.

Industrial Applications

Power Generation: LP turbine exhaust condensate collection in combined-cycle plants, cogeneration facilities, and district heating systems

Refinery Operations: Vacuum column overhead condensate, atmospheric distillation condensate, and staged separation systems

Petrochemical Processing: Low-pressure fractionation condensate, reactor cooling system drains, and utility steam condensate

Steam Distribution Networks: Final-stage flash tanks in cascade systems, condensate return header collection, and pressure-reducing station drainage

Chemical Manufacturing: Process vessel jacket condensate, heating coil drainage, and reaction cooling system collection

Technical Specifications

• Design Standards: ASME Section VIII Division 1, ASME B31.1, API 510
• Operating Pressures: 5 psig to 50 psig typical range
• Capacity Range: 100 gallons to 5,000+ gallons
• Materials: SA-516 carbon steel, SS 304/316/316L, special alloys for corrosive service
• Temperature Range: 200°F to 300°F typical operating conditions
• Configurations: Horizontal or vertical orientation, skid-mounted or field-erected
• Testing: Hydrostatic test, radiographic examination, pneumatic leak testing
• Relief Protection: Pressure safety valves sized per API 521 methodology

Project Execution and Support

In-house engineering capabilities include process simulations, separation efficiency calculations, and materials selection optimization. 3D modeling enables clash detection and installation planning before fabrication begins. Performance guarantees ensure vessels meet specified separation efficiency and capacity requirements.

Experienced project management coordinates fabrication schedules, quality control inspections, and shipping logistics. Strategic location at Mersin port provides efficient access to Middle Eastern, European, and global markets with competitive transportation costs.

Construction supervision services support field installation activities, with technical representatives available for hydrostatic testing, instrumentation calibration, and commissioning assistance. Operator training programs ensure plant personnel understand proper operating procedures and maintenance requirements.

After-sales support includes spare parts availability for instrumentation components, periodic inspection services, and technical consultation for process modifications or capacity expansions. Long-term maintenance contracts provide scheduled inspections, performance testing, and equipment refurbishment.

LP condensate drums deliver reliable vapor-liquid separation and condensate collection through proven engineering, quality fabrication, and comprehensive system integration from design through operational support.