How Much Does a Condensate Pot Cost?

When planning or maintaining a pressure instrumentation loop, one of the most common questions engineers and procurement teams face is: how much does a condensate pot cost? The answer, as with most specialized process components, depends on several interrelated factors. Condensate pots, sometimes referred to as seal pots or condensate chambers, serve a critical role in steam and differential pressure measurement loops by trapping condensate and protecting transmitters from direct steam contact. Their cost varies widely depending on material selection, design pressure rating, volume, coating, and quality assurance requirements. Understanding these drivers will help you make informed decisions that balance budget, performance, and reliability.

Condensate Pot Cost: Typical Prices & What Drives Them

The condensate pot cost can range anywhere from $150 to over $1,200 per unit, depending on the build specification. Off-the-shelf, uncoated carbon steel pots designed for moderate pressures and standard 2″ pipe size typically fall at the lower end. By contrast, custom-fabricated stainless or exotic-alloy pots designed for high-pressure or corrosive service, with NDE, certification documentation, and protective coatings, sit at the upper end of that range.

Key cost drivers can be grouped into several categories:

• Material and alloy selection (carbon steel, stainless steel, chrome-moly, Inconel, etc.)
• Pressure rating and wall thickness
• Volume or internal capacity (commonly 0.5–2 liters per leg)
• Fabrication complexity and number of welds
• Coatings, passivation, or paint systems
• Inspection and NDE requirements (e.g., radiography, PMI, hydrotesting)
• Certifications and documentation packages
• Lead time and order size

Each of these elements can significantly impact both the direct cost and the sourcing timeline. For example, specifying a 316 stainless pot for offshore service might increase unit cost by 60–80% compared to carbon steel but eliminate the need for external coating and reduce lifecycle maintenance costs.

Condensate Pot Cost by Material, Volume & Ratings

Material Selection and Cost Implications

Material is almost always the single largest determinant of condensate pot cost. The choice depends on both process medium and environmental conditions.

• Carbon Steel (A106 or A105): Typically the most economical material option. Carbon steel pots are ideal for standard steam loops in refinery or power plant environments where corrosion risk is moderate. Prices usually range from $150 to $300 each in 2″ nominal size.
• Stainless Steel (304/316): A premium option for corrosive services, outdoor installations, or systems using aggressive fluids. Expect pricing from $350 to $700 per pot, depending on rating and wall thickness.
• Chrome-Moly (P11, P22, P91): Required for high-temperature, high-pressure steam circuits. These are more expensive and may require PWHT (post-weld heat treatment), pushing the cost between $600 and $1,000.
• Nickel Alloys (Inconel, Monel, Hastelloy): Used in specialty chemical and offshore environments. These are highly corrosion-resistant but significantly costlier, with prices typically $900 and above, often exceeding $1,500 for certified builds.

Volume and Wall Thickness

Condensate pots come in a range of capacities, typically from 300 ml to 2000 ml. Larger volumes increase both material and fabrication costs, particularly when wall thickness grows to meet high-pressure ratings. For example:

• A 1-liter carbon steel pot rated for 600 PSI may cost around $200–$250.
• A 2-liter stainless steel pot rated for 1500 PSI can approach $600–$750.

In critical loops where condensate stability or phase separation is vital, larger-volume pots may be required to ensure measurement reliability. However, it’s important to remember that increased volume adds not only to cost but also to installation footprint and support requirements.

Pressure Rating Considerations

ASME and client design specifications typically dictate the pressure class (e.g., Class 150, 300, 600, 900, 1500). The higher the pressure rating, the thicker the wall section and the more rigorous the weld qualification requirements.

Each jump in class roughly increases base cost by 20–40%, primarily due to:

• Additional raw material mass
• Longer machining time
• More stringent QA/QC inspection
• Potential requirement for PWHT

For example, a 316 SS pot rated for Class 600 may cost $550, while a Class 1500 version of the same design could exceed $900.

Condensate Pot Cost: Coatings, NDE, and Certifications

Coatings and Surface Treatments

Coatings are a secondary cost driver often overlooked until late in the procurement process. Depending on service conditions, options include:

• Zinc-rich primer and epoxy topcoat for external protection in humid environments ($40–$80 extra per pot).
• High-temperature aluminum or ceramic coatings for steam service exceeding 400°F ($60–$120 per unit).
• Internal epoxy or phenolic linings for wet service or sour gas environments ($100–$200+ per unit).
• Passivation for stainless steel to remove free iron and improve corrosion resistance ($20–$40).

Each coating system may also add several days to lead time for curing and QA documentation.

NDE (Non-Destructive Examination)

Condensate pots used in critical measurement or safety loops often require NDE, such as:

• Radiography or ultrasonic testing (RT/UT) for weld verification
• Liquid penetrant (PT) or magnetic particle (MT) inspection
• Positive material identification (PMI) to verify alloy composition
• Hydrostatic or pneumatic pressure testing per ASME standards

Adding NDE can increase unit costs by $100 to $300, depending on the level of inspection required. For example, 100% RT on all welds can double fabrication inspection time.

If full traceability to ASME Section IX or API 6A is required, additional documentation, stamping, and record-keeping may add further cost and administrative overhead.

Certifications and Data Packages

For oil, gas, and power projects, a complete manufacturer’s data report (MDR) or dossier can be as critical as the component itself.
Common inclusions:

• Material test reports (MTRs)
• Weld procedure qualification records (WPQRs)
• Heat treatment charts
• Dimensional and hydrotest certificates
• Coating certificates and NDE reports

A full documentation package may add $50–$150 per pot in administrative cost, but can be essential for traceability and future audits.

Buy vs Fabricate: Quality, Traceability, and Delivery

Purchasing from a Manufacturer

Buying directly from a reputable supplier ensures compliance with material and design codes (such as ASME B31.1 or B31.3). It also guarantees traceability for material certificates and weld procedures. Standard condensate pots in carbon or stainless steel are typically stocked items, allowing for rapid delivery in 1–3 weeks, depending on size and finish.

Purchasing advantages include:

• Certified materials and welders
• Factory pressure testing
• Consistent weld quality
• Standardized documentation
• Faster turnaround

While the upfront cost may be slightly higher than in-house fabrication, the savings in QA/QC time, inspection risk, and potential rework more than compensate for the price difference.

Fabricating In-House

Some plants choose to fabricate condensate pots internally, particularly when they have pressure vessel code facilities. The cost per pot can be as low as $100–$150 for carbon steel, but that doesn’t include hidden costs such as:

• Labor and shop time
• NDE, hydrotesting, and documentation
• Quality assurance oversight
• Risk of nonconformance or rejected welds

Unless your facility already holds ASME certification and the required traceability systems, internal fabrication is rarely cost-effective for small batches.

Condensate Pot Cost: Lead Times, MOQs, and Supply Risk

Typical Lead Times

Lead times depend on material availability and workload at the fabrication facility. Here’s a general benchmark:

• Carbon steel standard pots: 1–2 weeks (stocked or quick-turn).
• Stainless steel: 2–4 weeks.
• Chrome-moly or exotic alloys: 6–10 weeks (may require special procurement).
• Custom-coated or NDE-heavy pots: Add 1–2 weeks for inspection and curing.

During periods of high demand or supply chain disruption, lead times can double, particularly for nickel alloys and special coatings.

Minimum Order Quantities (MOQs)

MOQs are typically modest, but for small, custom runs, the setup cost may drive per-unit pricing higher. Many machine shops require a minimum order of 2–4 units to justify the tooling and welding setup. For exotic materials, the MOQ might be 6–10 units if bar stock or pipe must be ordered in standard lengths.

Supply Risk Factors

The largest risks to delivery and price stability include:

• Material shortages for alloy steels or nickel-based metals
• Coating vendor backlogs
• NDE bottlenecks for certified inspectors
• Logistics delays for international shipments

Mitigation strategies include sourcing from multiple qualified suppliers, maintaining a buffer stock of common materials, and locking in pricing early in project planning. Working with a well-established machining and fabrication company with proven supplier relationships is the best safeguard against schedule slippage.

Mounting, Valving, and Installation Accessories

While the condensate pot itself is the core component, several associated accessories are often purchased together and can meaningfully affect total installed cost. These include:

• Mounting brackets and supports
• Drain and vent valves (typically needle valves or mini ball valves)
• Instrument manifolds
• Compression fittings or flanged connections
• Insulation jackets for outdoor or steam service

A complete installation kit, including the pot, valves, and fittings, can cost $500 to $1,500 per assembly, depending on the configuration. Many suppliers offer fully assembled, pressure-tested units that reduce field labor and eliminate compatibility issues.

When comparing quotes, ensure the scope is identical. Some vendors include valves and brackets in the base price, while others list them as add-ons.

Sourcing Tips for Pressure Instrumentation Loops

To optimize both cost and reliability, consider the following best practices when sourcing condensate pots and related components:

1. Standardize Your Specifications: Create a standard design for each material and pressure class used in your facility. This reduces engineering hours and allows volume pricing.
2. Consolidate Orders: Ordering multiple sizes or materials from a single vendor reduces freight and administration costs.
3. Prequalify Vendors: Verify that your supplier maintains certified welders, up-to-date ASME code stamps, and traceable materials.
4. Request Digital Documentation: Electronic MDRs speed up project closeout and reduce manual errors.
5. Plan Ahead for Exotic Materials: Alloys such as Inconel or Monel can have 8–12 week lead times due to limited global stock.
6. Ask About Alternate Materials: Sometimes, 304 SS or P22 can substitute for higher-grade materials when design margins allow.
7. Bundle NDE and Coating Services: Integrated fabrication and coating vendors minimize logistics risk.
8. Confirm Test and Certification Requirements Early: Delaying this clarification can add thousands to inspection costs late in a project.

The True Cost of Quality and Reliability

When evaluating condensate pot cost, the lowest bid isn’t always the best value. Quality assurance, inspection, and documentation are crucial for safety-critical loops, and a small saving per pot may lead to costly rework or downtime if a failure occurs. The total installed cost should account for not only fabrication and freight but also engineering time, inspection labor, and field installation.

Partnering with a specialized machining and flow measurement manufacturer provides both technical assurance and logistical simplicity. Experienced suppliers understand the nuances of metallurgy, welding codes, and pressure system integrity. They can also tailor lead times and testing plans to your project schedule, something that’s often difficult to achieve through ad-hoc fabrication.

Why Flowell Corporation Is Your Best Choice

For over 30 years, Flowell Corporation has been the trusted partner of choice for oil and gas, power generation, and process industries needing precision-machined flow measurement components. Based in Tulsa, Oklahoma, Flowell delivers unmatched quality in custom condensate pots, manifolds, and flow accessories built to ASME and API standards.

Our team of skilled machinists and engineers ensures every product meets the highest levels of accuracy, reliability, and traceability. Whether you need standard carbon steel pots or specialized stainless and alloy builds with full certification, Flowell provides the quality and documentation your projects demand, on time and within budget.

Contact us today to discuss your condensate pot requirements, request a quote, or explore custom-engineered solutions. From machining excellence to precision instrumentation support, we are your premier destination for condensate pots and flow measurement solutions.