Condensate receiver tanks collect returned condensate before it is pumped back to the boiler feedwater system. They operate as the buffer between the steam distribution network and the boiler house, and their instrumentation and safety devices must be maintained for reliable operation.
AQ Process Systems sources and exports level controls, float valves, sight glasses, safety valves, and all associated fittings for both atmospheric (vented) and pressurised condensate receiver tanks. We also supply replacement gaskets, manholes, and internal components.
Proper maintenance of condensate tank level controls is critical, a failed level control can cause pump cavitation (low level) or tank overflow and flash steam venting (high level), both of which waste energy and create safety hazards.
| Component | Specification | Description |
|---|---|---|
| Level Control | ||
| Float Switches | SS float | SPDT/DPDT | High/low/pump control | Mechanical float switches controlling pump start/stop and high/low level alarms. |
| Level Transmitters | DP, capacitance, or ultrasonic | Electronic level transmitters for continuous level monitoring and control system integration. |
| Sight Glasses / Level Gauges | Tubular or flat glass | With isolation valves | Visual level indicators, tubular sight glasses or flat glass gauges with automatic isolation ball checks. |
| Overflow Devices | Float-operated or weir type | Tank overflow protection, preventing overfilling when condensate return exceeds pump capacity. |
| Valves & Fittings | ||
| Vent Fittings | Atmospheric vent head | SS mesh screen | Tank vent assemblies allowing flash steam escape while preventing debris ingress, with mesh screens. |
| Drain Valves | Gate or ball | Manual or actuated | Tank drain and blowdown valves for sediment removal and maintenance draining. |
| Isolation Valves | Gate or butterfly | Flanged | Inlet, outlet, and bypass isolation valves for tank maintenance without system shutdown. |
| Check Valves | Swing or wafer | Condensate return lines | Non-return valves on condensate return lines preventing backflow to steam traps and process equipment. |
| Tank Components | ||
| Manhole Covers & Gaskets | CS | Bolted access | Spiral wound gasket | Inspection manhole covers with gasket sets, for internal tank inspection and cleaning access. |
| Nozzle Connections | Flanged | CS or SS | Replacement nozzle connections for corroded inlet, outlet, vent, drain, and instrument fittings. |
| Internal Baffles | CS or SS plate | Internal baffles preventing turbulence and promoting condensate de-flashing before pump suction. |
| Corrosion Protection | Epoxy lining or SS cladding | Internal corrosion protection, epoxy coating, SS lining, or sacrificial anode systems for carbon steel tanks. |
Parts are matched to OEM material specifications and dimensional tolerances. Please provide the equipment manufacturer, model number, and serial number (if available) for precise part identification.
The most common spares are level controls (float switches, transmitters, and sight glasses), vent fittings (corrosion and blockage), gaskets (manhole and nozzle gaskets replaced during inspections), drain valves, and check valves. Internal corrosion protection (lining or coatings) may need refurbishment every 5-10 years.
Float switches and level transmitters should be functionally tested quarterly, verifying pump start/stop, high level alarm, and low level cutoff operation. Sight glasses should be inspected monthly for clarity and leakage. Annual calibration of electronic level transmitters is recommended.
Yes. Atmospheric (vented) tanks are the most common in industrial steam systems. We also supply parts for pressurised condensate receivers used in high-pressure condensate recovery systems, including rated safety valves, pressure gauges, and pressure-rated level instruments.
Excessive flash steam from the tank vent usually indicates that high-pressure condensate is entering the tank, either from failed steam traps passing live steam, or from high-pressure condensate flashing at the lower tank pressure. Installing a flash vessel upstream of the tank, or repairing failed steam traps, will reduce the flash loss.
Yes. Internal corrosion can be addressed by abrasive blasting and re-coating with high-temperature epoxy, or by installing a stainless steel internal lining. For severe pitting, weld repair followed by re-coating is common. We supply corrosion protection materials and can advise on the repair approach based on the tank condition.
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