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SMART VALVES STEAM TRAPS

Can Venturi Steam Traps Work on Variable Load Conditions?

2021-06-19

A steam trap is a device that is used to discharge condensate and non-condensable gases from a steam system while preventing the leakage of any live steam. The principle behind the working of a conventional mechanical-type steam trap is similar to that of an automatic valve that opens, closes, or modulates automatically, thereby filtering the condensate out from the steam system.

However, the downside to the mechanical-type steam traps is that they are easily prone to failure due to the presence of moving mechanical parts that often get stuck in either open or closed position, thus resulting in the loss of live steam from the system or producing a water hammer effect that can often end in a catastrophe. To counter this issue of frequent failure of the mechanical steam traps, there are other more efficient types of steam traps available in the market known as the orifice type steam traps. What’s good about the orifice-type steam traps is that they do not contain any moving mechanical parts, thus greatly reducing their chances of failure. But the question is, how do they function without any moving parts?

As opposed to a conventional mechanical-type steam trap, the orifice-type steam traps continuously remove condensate from the system as soon as it is formed. The principle behind the working of these steam traps is the density difference between steam and water. When there is low pressure, the density of steam is 1000 times lower than that of the condensate. Therefore, when both steam and condensate are present, the trap only allows the much denser condensate to discharge while preventing the passage of steam through its orifice. In other words, no live steam is allowed to leak from the trap. Now, orifice-type steam traps can be divided into two types: 1) fixed or plate orifice trap and (2) venturi orifice traps. Although both the types work on the same principle described above, there is one key difference between them.

In a fixed or plate orifice trap, a small orifice of pre-determined diameter is punched into a plate. This diameter of the orifice is calculated on the basis of the condensate flow and pressure that is going to be experienced by the trap in running conditions. However, in practice, there can be significant variations in the steam pressure and the condensate loads. For example, there can be a great difference between the start-up and running loads as well as significant changes in steam pressure due to the temperature at which the system is operating. As a result of these varying conditions, the fixed orifice which is designed to operate at a certain pressure and condensate flow can either hold back condensate or allow the steam to pass, thus affecting the performance of the plant as well as compromising its safety.

The sizing of the fixed orifices is often a compromise between the start-up and running conditions in order to minimize the effects of waterlogging, prevent live steam from escaping the system, and maximize the filtering of condensate. However, the conditions, in reality, can vary a lot which can render the fixed orifice steam traps useless in most cases. Of course, a proper steam trap should be the one that has no moving parts in it and can still be able to work optimally at all varying conditions. It should be able to efficiently filter out the condensate from the system without leaking any live steam, regardless of the conditions of load or pressure.

This is where venturi-type steam traps come in. A venturi-type steam trap works on exactly the same principle as the fixed or plate orifice trap, but with one key difference — It can handle variable load conditions. In addition to the orifice, a venturi-type steam trap has an ingeniously configured staged throat that is specifically designed to handle the variable load conditions. With a staged throat, the venturi steam trap is able to create variable backpressure at the orifice with the changes in load. When the flow rate is lower, the condensate flashes close to the orifice while at a higher flow rate, it flashes further down the stage throat. As a result, the flow of condensate through the orifice is restricted on the basis of the load, allowing the venturi trap to self-regulate its capacity across varying load conditions. This makes venturi-type steam traps suitable for most use cases.

Unfortunately, there has been a very slow rate of adoption of venturi-type steam traps in the U.S, despite the technology been available since the 1980s. The possible reasons could be the lack of awareness and the skepticism that they might not work on variable load conditions. However, in reality, the venturi-type steam traps manufactured by SMART Valves Inc. are much more efficient than conventional mechanical steam traps on variable load conditions and are very less likely to fail.

We are not just making this claim out of thin air, but there is independent and objective laboratory testing by GTI backing this claim. GTI conducted laboratory testing to compare the efficacy of our venturi steam traps, known as SMART steam traps, against comparably sized mechanical steam traps at different pipe sizes, pressures, and condensate loads. The testing was conducted based on the American Society of Mechanical Engineers Performance Test Code (ASME PTC) 39 – 2005 standard for measurement of steam losses in a purpose-built, instrumented steam loss piping circuit with the adjustable process operating conditions.

After performing 134 test trials at different conditions, the results demonstrated that our venturi-type steam traps were able to efficiently discharge variable condensate loads safely across a range of steam pressures, which was perfectly in accordance with the industry requirements. Even when our steam traps were subjected to conditions outside their specified operational range, they were able to operate efficiently under these conditions, discharging condensate much more effectively than mechanical steam traps.

So, what are you waiting for? Get rid of the hassle that comes with the constant need for maintaining and replacing conventional mechanical steam traps. Let our technology make things easy for you and provide you with a permanent and cost-effective condensate removal and steam trapping solution. Make a smart choice now and request a 90-day risk-free SMART steam trap trial today.

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