Electronic Condensate Controller

After 3 months of continous operations the first Electronic Condensate Controller has preformed all required operational processes with no reported operational issues or concerns. The most amazing test was when the Steam was turned on for winter heating and the condensate from Steam Heaters in 3 buildings was added to the ECC along with the condensate from the Steam Screw Sludge Press. This test proved the ECC can process condensate comming from at least 2 different sources with no operational issues or concerns. Continued addition of more condensate sources being connected to this ECC fot testing is possible. The Inlet Supply Steam to Screw Sludge Press varies depending on systems needs, from 30 to 50 psi, The Building Heat Inlet Steam Supply operates at 15 psi. The condensate from both sources go directly to the Electronic Condensate Controller which continued to operate normally with only small operational changes being noticed and recorded when condensate from heating systems first flowed into the ECC unit, The Steam Heating System is operating with none of the previous normal old trap problems. No recorded issues or operational problems reported on any operating systems since combining of the 2 condensate soruces 4 weeks ago. Donnie H

This Article is from K & H Energy Systems Inc.

STEAM TRAPS VS AUTOMATED CONDENSATE CONTROLLERS

Know the difference of using one or the other

TheConceptof Steam traps

Steam Traps traditionally have been considered as a "trap" for steam only. It means that the steam trap had the competence of removing the (liquid) called condensate as soon as it is accumulated upstream of the trap.

This restricted point of view has firmly been fixed in our mind as a consequence of the slow evolution of steam traps.

In fact, during decades the Steam Trap has been considered as an on - off valve unable to control energy, but differentiates between water and steam (float and inverted bucket traps). The arrival of thermodynamic steam traps did not change that way of thinking, but instead contributed to waste energy, reinforcing the old idea of "trapping".

Although the Condensate Control Valve (thermostatic steam trap) was developed to improve and replace the old steam trap idea, most people associated the on-off operation principal (trap concept) to the thermostatic steam trap.

Presently, manufacturers and users defend their position according to their interests; experience, or any other reason, without analyzing technically the consequences of using any of these concepts.

The Modern concept of Energy Control Valves,

Now days the concept of steam trap additionally involves the idea of controlling the energy discharged through the valve, as well.

Then we should say steam traps when we talk about mechanical or thermodynamic steam traps, reserving a new name, condensate controllers or condensate drain valve systems for example, when talking about modern condensate control systems.

Trapping versus Controlling Condensate Energy,

Concepts are easier understood when we analyze the old global problem (the tree does allow seeing the forest).

Consider the simplified steam installation. The steam producer (boiler) is connected to the energy users through the steam distribution lines (high energy level) and the condensate return system (low energy level).

Trapping steam means creating a physical barrier between the steam zone and the condensate region (the old "trap concept).

The trap discharges condensate at saturated temperature (maximal remaining energy) producing flash steam in the return collector.

That way, backpressure increases downstream of the trap and thermal water hammer often occurs. Excess of remaining energy is lost along the return system or discharged to the atmosphere at the condensate receiver tank.

Controlling Condensate energy means not only establishing a boundary between two zones at very different levels of energy, but controlling the transition between both zones. With the condensate "control" valve concept discharge of condensate is controlled automatically, which means that remaining Energy is Efficiently reduced to low level Temperatures (releases more Latent Heat in the Steam User) reducing Flash Steam, Water Hammer, and often reduces Steam Energy Consumption by as much as 15%, while also reducing a portion of air contamination.

The trap concept is necessary only in a few applications while Controlled Discharge of Condensate can be applied on the majority of situations. It should be clarified that most typical "trapping" examples must be considered as "controlling" applications.

When Trapping and Controlling Condensate Energy,

Conventionally "trapping" was suggested when we need be sure that no condensate is upstream of the trap and "controlling" is used when we need to save energy.

Condensate return systems at large installations (oil refineries, petrochemical plants, and Pulp and Paper facilities, etc) are very sensitive to persistent problems caused by back pressure and water hammer. It is strongly recommended to use the "controlling" condensate energy concept to prevent these occupancies.

The condensate energy controller's evolution (automated condensate controllers) makes it difficult to find applications where they cannot be successfully applied.

Checking "Traps" or "Condensate Energy Controllers"

No matter what type of steam trap is being used it is necessary to establish a periodically testing program to determine the working condition to ensure that they are not leaking steam (failed open) or water logged (failed closed).

To check "condensate Energy Controllers" we need only to check the pressure into the controller and the pressure out of the controller.

Intelligent Condensate Energy Control System These systems combine condensate controllers with continuous monitoring devices, such as electronic line monitoring equipment that measures pressure and temperature into and out of these condensate controllers. These systems add the advantage of setting and reporting conditions on line without stopping or altering the units operation. That performance gives it one formable tool to solve the very different problems of back pressure or water hammering in condensate collecting and storage devices. Improving energy efficiency, reducing maintenance costs and reducing energy consumption...

Monitoring systems applied to the concept of "trap" have reduced interest due to the following reasons:

O The trap concept wastes energy and is condemned to disappear.

O Traps generate serious problems.

O Traps cannot be repaired while in operation.

Conclusion,

Over many decades steam traps has slowly mechanically improved.

At present, the incorporation of electronics on intelligent condensate energy controllers (the newest and most dependable energy controllers in the 21^st Century), which satisfactorily solves most important problems derived from the growing size of installations and the continuous energy price increases. Intelligent condensate controllers easily reduce energy consumption up to 15% at steam installations.

This Article is from K&H Energy Systems Inc. Hie Sheppard a Steam Engineer for over 55 yrs has designed, built, tested, patent, the first Electronic Condensate Controller. For more Information, Check our website; K & H Energy Systems

mailto:khengsys@aol.com

Re: Electronic Condensate Controller DonnieH

After 15 months of continuous service with no reported issues or problems, I personally have check first installed ECC every working day as it is installed I where I am employed. The next big challenge is a planned installation trial using the ECC on a Liquor Heater for a Pulp Digester. A Pressure Vessel like a digester holding a 100 tons of chips has more recorded data than a sludge press drying sludge from large clarifier tanks drying over 10 tons of sludge day. The Steam flow to the digester liquor heater is anywhere from 10,000 lbs to 40,000lbs depending on type of pulp and what cooking curve is being used. I hope to have some data available in a few months on the outcome of this Trial and if the company wants to purchase several more ECC for the remaining digesters they have. Our program to offer a trial with any interested company, where we can engineer and supply and ECC, if an agreement is approved between both companies there is no charge during the agreed upon trial period and if the ECC did not meet or exceeded their specifications, they could return it at no cost or purchase it at a previously agreed price. Proving the ECC is Efficient is our goal, if we can reduce fuel consumption by 15% and still produce the same factory production means it will also reduce 15% of Green House Gases going up the Stack. Thank you