The job of a steam trap is: 

• 1) to keep steam in the system
• 2) to purge condensate from the system quickly and efficiently
  

These functions are important for preventing problems such as poor heat transfer, corrosion, erosion and water hammer.  The permanent condensate removal system does a better job on both the hot steam side and the cold condensate side of the trap, resulting in a greater temperature differential across the trap. 

1) Keeping steam in the system:

The venturi orifice trap starts out about 5% more efficient than a new mechanical steam trap, and retains its initial efficiency indefinitely.  A technician accurately sizes each venturi condensate removal unit for the full range of condensate loads.  There is a common misconception that the orifice trap will leak steam.  If the flow were laminar, this would be the case.  Instead, the permanent  traps operate on the basis of turbulent flow.  When the load drops below 100% capacity, the orifice passes a violently turbulent mixture of equivalent volumes of steam and water.  Steam, several hundred times lighter than condensate, tries to pass through the orifice at close to the speed of sound, but is impeded by any condensate present. The steam continuously forces the much denser condensate (traveling about 48 kph) into the orifice, effectively blocking the steam from passing through. 

An accurately sized unit loses .39 kg/hr (1.76 lbs/hr) of steam with a load that drops to 25% in a 700 kpa (100 psi) system producing 170 kg/hr (375 lbs/hr condensate). A brand new mechanical steam trap will lose more than an Enercon unit, and a failed conventional trap, according to the Department of Energy's 'Leaking steam trap discharge rate', with a .05 cm (1/8") opening loses 24 kg/hr (52.8 lbs/hr).

If it is operating properly, a mechanical steam trap with an oversized orifice opens and closes about 6 times a minute.  Each time the mechanical trap opens there is a small pressure drop. This can be demonstrated at any plant.  While the pressure drop is small, in a system with 100 traps, this equals 36,000 small pressure drops every hour.  The permanent system eliminates these pressure drops, improving heat transfer in the system. 

Mechanical traps remove condensate cyclically.  Because they are constantly opening and closing, they wear, leak and then fail.  The venturi traps have no moving parts that can fail. 

2) Purging condensate quickly and efficiently

The venturi system removes condensate with a continuous flow that happens so rapidly that there is virtually no time for the condensate to cool and collect in the steam coils. Steam is heat and water, and when the heat is lost, steam turns back to water.  In steam systems with mechanical steam traps, when heat from steam is lost, vapor condenses to the bottom of the pipe and finally makes its way to the mechanical trap.  With the permanent condensate removal system, the constant change in pressure and the continuous flow result in significantly less condensed water on the heat transfer side of the equipment.  The BTU count is higher in the heat transfer chamber and water isn't acting as an insulator.  Condensate is eliminated from the system immediately.  Water hammer, corrosion and other problems caused by excess condensate in the system will be greatly reduced, making the work environment safer.  

As more of the system is converted to the venturi condensate removal units, the more operational and fuel saving benefits the customer will gain. (See System Conversion).

The keys to a successful venturi system installation are:

1) Expertise in steam systems and sizing orifices for each application
2) Durable hardware
3) Lifetime Warranty

Our supplier, Enercon Systems, has been specializing in venturi orifice systems since 1989.  Enercon has developed the steam knowledge and extensive database of application information to be able to make each installation successful.  A technician ensures that every unit shipped qualifies for an orifice.  The Enercon venturi orifice trap is made of a one-piece stainless steel unit with a y-strainer and a blow down valve. It is a permanent installation that is sized specifically for each application so as to choke off the flow of steam without preventing the condensate from bleeding off and returning to the boiler.  There are no moving parts that can fail, and Enercon's stainless steel condensate removal units have a Lifetime Warranty -- the best warranty in the business.

Some Enercon traps have been in place as long as 19 years with no repairs or replacements and no loss of efficiency. There are approximately 1,000 plants with Enercon orifice traps installed, and 240 of these plants have converted all of their mechanical traps to Enercon traps.  The unit has a precisely drilled hole and is made with the correct stainless steel metal so that it will withstand erosion over time and provide a long life of service. In plants without existing plugging problems, the plant will not experience plugging. (See Installation)