Measure Overview
This measure would require newly constructed process steam systems and new, non-replacement process steam loads at existing facilities that meet a set of criteria to install a condensate return system that returns all uncontaminated condensate to the boiler plant for reuse, including condensate from associated drip legs. Condensate return from direct steam injection (that comes in direct contact with the process) is not part of the proposed requirement.
Newly constructed process steam systems and new, non-replacement process steam loads would qualify for the requirement if they:
- have one or more connected boilers with an input rating (capacity) of 10 MMBtu/h or greater,
- use indirect-contact heat exchangers,
- generate condensate during normal operation, and
- meet the criteria for load size and condensate return piping lengths in Table 1.
Table 1: Condensate Return Code Trigger Criteria
| Steam Flow (lb/h) | Linear Length1 (ft) less than |
| <1,000 | Exempt |
| ≥1,000, <2,000 | 350 |
| ≥2,000, <3,000 | 600 |
| ≥3,000, <3,500 | 800 |
| ≥3,500 | 1,000 |
Compliance with this measure would be demonstrated through documentation on construction documents.
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This measure page will be updated as the 2028 code cycle progresses. For questions or suggestions, email [email protected]. Please include the measure name in the subject line.
Scope of Proposed Code Change
| Building Type(s) | Construction Type(s) | Type of Change | Updates to Compliance Software | Third Party Verification |
| Nonresidential | New construction, additions, alterations | Mandatory | No updates | No changes to third party verification |
Justification for Proposed Change
In process steam systems, condensate is formed when steam releases its heat of condensation in a heat exchanger and condenses into liquid. Facilities that recover condensate reduce the need for make-up water, pre-heating fuel, and chemicals for water treatment. Some sites may also benefit from a reduction in wastewater costs. Because condensate is effectively distilled water, its recovery also reduces the need for boiler blowdown, which results in additional energy savings.
Department of Energy (DOE) literature has recommended increasing the percentage of returned condensate as a steam system best practice in since at least the early 2000s, and the DOE provides a steam tip sheet specifically on improving condensate return. This proposed code change originated from discussions with California-based consulting engineers from strategic energy management programs and the DOE Industrial Assessment Center program.
Depending on site conditions, this measure is expected to yield energy savings of approximately 5% to 8% of baseline boiler system fuel use. There are two main sources of savings: (1) the energy difference between returned condensate and cold makeup water and (2) reduced blowdown losses resulting from increased condensate return.
To the knowledge of the Statewide CASE Team, condensate return requirements have not been proposed in previous code cycles. In 2013, Title 24 Part 6 first adopted requirements for process boilers. In 2022, Title 24 Part 6 adopted requirements for strainers and fault detection and diagnostics in steam trap assemblies.
Relevant Documents
Round One Utility-Sponsored Stakeholder Meeting Materials
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The Statewide CASE Team values input from all stakeholders engaged in the Title 24, Part 6 code change process. We encourage the open exchange of code change comments and concerns.