A condensate manifold collects condensate from multiple steam traps into a single header and returns it to the boiler house or a recovery unit. JBM manifolds cover header and forged block designs from 25 to 150 NB with 4 to 16 inlets, with or without integral trap stations, for plant condensate, tracer returns, clean steam condensate, and flash steam recovery, reducing energy and water losses by returning hot condensate.
Each trap discharges into its own inlet on the header through a non-return valve, so traps at different pressures do not back up into each other. Inlets enter from the top or side to avoid backflow. The header slopes toward the outlet, and flash steam formed as hot condensate drops in pressure is vented or sent to a flash vessel for reuse. Test and blowdown valves on each inlet allow trap checking without disconnection.
Challenges
Trap Backpressure
Traps at different pressures push against each other in a shared header.
Flash Steam Load
Flash steam reduces header capacity and causes noisy two-phase flow.
Trap Failure Detection
Failed-open traps waste steam and are hard to locate in a group.
Corrosion
Carbonic acid in condensate corrodes carbon steel headers.
Maintenance Access
Scattered traps are slow to inspect and replace.
Solutions
- Non-Return Valve per Inlet: Check valves isolate each trap from header backpressure.
- Flash-Sized Headers: Header sized for flash steam volume, not liquid flow alone.
- Test and Blowdown Valves: Each trap checked visually or with sensors without disconnection.
- SS304 / SS316L or Sch 80 CS: Corrosion allowance or stainless construction for long life.
- Integral Trap Stations: All traps grouped at one accessible manifold.
Applications
- Pharmaceutical: Jacket and autoclave condensate, clean steam condensate.
- Food & Beverage: Cooker, kettle, and pasteurizer condensate recovery.
- Chemical: Tracer and reboiler condensate collection.
- Utilities: Condensate recovery to boiler feed tanks and flash vessels.
Types & Configurations
| Type | Code | Design & Operation | Size / Inlets | Rating | Typical Use |
|---|---|---|---|---|---|
| By Construction | |||||
| Header-Type Condensate Manifold | HD | Pipe header with inlet stubs and check valves | 25–150 NB; 4–16 | 150# | General condensate return |
| Forged / Block with Integral Trap Connections | FB | Forged body with universal trap connector ports | 15–25 NB ports; 4–12 | Up to 32 bar | Compact trap stations |
| By Function | |||||
| Condensate Return Manifold | CR | Collects discharge from multiple process traps | 25–150 NB; 4–16 | 150# | Plant condensate return |
| Tracer Condensate Collection | TC | Groups tracer line traps at one point | 25–50 NB; 8–16 | 150# | Tracing systems |
| Clean Steam Condensate Manifold | CS | SS316L, orbital welded, fully drainable | ½”–2” OD; 4–10 | Up to 6 bar | Clean steam drains |
| Flash Steam Recovery Manifold | FR | Header with flash vessel connection for LP steam reuse | 50–150 NB; 6–16 | 150# | Energy recovery |
| By Configuration | |||||
| Integral Steam Traps (TD / Float / Thermostatic) | -IT | Trap, strainer, and isolation valves on each inlet | 15–25 NB traps | Up to 32 bar | Complete trap stations |
| Test / Blowdown Valves per Inlet | -TB | Test valve and blowdown valve on every branch | All sizes | As header | Trap monitoring |
| Pumped Condensate Manifold | -PC | Header discharging to a pressure-powered or electric pump unit | 50–150 NB | 150# | Lifting condensate to return lines |
Models & Sizes: 25 to 150 NB Header
| Model | Header NB | Inlets [nos] | Inlet NB | Length [mm] | Condensate Load [kg/h] | Rating | Weight Manifold [kg] | Weight with Traps [kg] |
|---|---|---|---|---|---|---|---|---|
| CM-025-04 | 25 | 4 | 15 | 750 | 180 | 150# | 15 | 40 |
| CM-040-06 | 40 | 6 | 15 | 1,000 | 450 | 150# | 20 | 55 |
| CM-050-08 | 50 | 8 | 15–20 | 1,250 | 750 | 150# | 25 | 90 |
| CM-050-10 | 50 | 10 | 15–20 | 1,500 | 750 | 150# | 30 | 110 |
| CM-080-10 | 80 | 10 | 15–25 | 1,750 | 1,800 | 150# | 45 | 150 |
| CM-080-12 | 80 | 12 | 15–25 | 2,050 | 1,800 | 150# | 50 | 170 |
| CM-100-12 | 100 | 12 | 15–25 | 2,050 | 3,200 | 150# | 65 | 190 |
| CM-100-16 | 100 | 16 | 15–25 | 2,650 | 3,200 | 150# | 85 | 250 |
| CM-150-16 | 150 | 16 | 20–25 | 3,050 | 7,000 | 150# | 140 | 330 |