COMMON QUESTIONS

How does the permanent condensate removal system perform at startup?

With properly-sized orifices, the permanent condensate removal system works better for plants during shutdown and startup. Initially, there will be a little backup, as there is with any trap system, but then the lines will clear and pressurize faster with the Enercon traps, because there is a specific flow direction for the condensate. The average startup time improvement is 25%.

Won't the venturi orifice traps leak steam? 

No. The venturi traps will improve efficiency, because they operate on the basis of turbulent flow rather than laminar flow.  The turbulent condensate, swirling violently, acts as a door, preventing steam from escaping.  At 68% condensate load, a new Enercon trap will lose virtually no steam. At 25% condensate load, the Enercon trap will not lose more than 1 kg (2 lbs) of steam per hour.  A new mechanical steam trap will usually lose more than 1 kg of steam per hour, and a blowing mechanical steam trap will lose much more.  If a plant has 100 mechanical traps, one blowing mechanical trap will exceed the acceptable steam losses of 100 Enercon traps.

Because the Enercon traps do not leak steam and cannot fail open, plants converted to the Enercon System do not have problems with higher-than-normal return line pressures.

Will the venturi traps work if I have widely varying loads? 

Yes. All loads vary to some degree, so if the venturi traps didn't work with varying loads, we would not be in business.  In plants that are completely converted, on average 99% of the mechanical traps have qualified for an Enercon orifice trap.  Large process applications will almost always have modulating control valves.  Systems with modulating control valves or solenoid valves will qualify for an orifice nearly 100% of the time, because the condensate load at the orifice itself will not vary much. 

What applications do not qualify for a venturi trap?

There is a very small percentage of applications that will not qualify for an orifice trap, because the load varies outside the guidelines.  In these cases, an Enercon technician will explain the reasons for the application not qualifying based on data. We will not ship an orifice trap unless it will work as well or better than a mechanical trap would for the application, or if the installation would not be cost-effective for the customer.

Will the orifice plug?

If you don't have plugging issues now, the Enercon traps won't plug.  If you have an issue with older piping that is flaking or leaving debris, there is a strainer in front of each orifice with a mesh that is smaller than the orifice opening.  The system is continuous flow, so anything smaller than the orifice will pass right through.  Orifices in the main header and main distribution system do a better job of stripping out the contaminated carryover than mechanical traps do.  If you have plugging issues, the source of the plugging will need to be located, and an Enercon technician can advise you on ways to address the problem.

How many plants have Enercon orifice traps installed in them?

There are about 1,000 plants with Enercon orifice units installed in the United States and Canada.  Of these plants, 240 are completely converted, including 38 for a $30 billion petrochemical company.  In completely converted plants, Enercon has replaced, on average, 99% of existing mechanical traps.  In the 1% of cases in which the mechanical trap was left in place, the Enercon technician advised the client not to convert to an Enercon trap for one of three reasons:  1) the loads fell outside the guidelines, 2) the system was not designed properly, and the customer was advised that additional equipment was needed, or 3) converting to an Enercon trap was not cost-effective.

How are Enercon orifice traps sized? 

Enercon traps are sized by an experienced technician who understands the orifice technology and how it applies to an individual steam system.  The technician sizes the trap for the maximum and minimum condensate loads. A steam survey will be done by the technician when we begin work with a plant. 

Why don't more companies use a permanent orifice system?

Most companies are more familiar with conventional steam trap systems.  An orifice condensate removal system takes more technical expertise in sizing and steam applications to implement than a conventional system and doesn't provide the regular repair and replacement income to trap companies.  However, with fuel prices increasing and maintenance staff in short supply, more companies are looking for an alternative condensate removal system.  The Enercon System is a proven permanent solution to condensate problems and inefficiencies in the steam system, with a fast payback that more companies are now implementing.

What kind of support can I expect?

We are committed to ensuring that each permanent condensate removal system works as well or better than the conventional trapping system it replaced.  We review post-installation results with each customer.  On occasion a correction needs to be made, in which case we send out an exchange, and the customer installs it.  The Lifetime Warranty of the Enercon system is the best in the business.  A steam survey includes 3 years of phone support at no charge.