How Venturi Steam Traps Prevent Water Hammer in Steam Systems

Water hammer is a serious issue in steam and condensate systems, often resulting in extensive damage to pipes, valves and equipment. This phenomenon occurs when pressure surges or waves form due to the sudden implosion of trapped steam or changes in direction of fluid movement, particularly when condensate is not efficiently removed. The cause of water hammer in steam systems is over pressure in the condensate lines often attributable to steam leakage through failed mechanical steam traps. The ECOFLOW™ steam trap utilises venturi orifice technology and provides a permanent solution to water hammer. Eliminating steam leaks and mitigating pressure fluctuations, thereby preventing water hammer.

Understanding Water Hammer in Steam Systems

Water hammer arises from increased pressure in condensate lines, often due to steam leaks. These leaks are prevalent in mechanical steam traps, which rely on sealing faces that open and close periodically. The nature of a mechanical seal means that over time the number of operating cycles will inevitably lead to wear and failure. When the seal fails it allows steam to escape, pressure fluctuations occur in the condensate line, contributing to water hammer. If left unchecked, water hammer can lead to ruptured pipes, valve failures, damaged heat exchangers, broken pipe supports and even injuries to personnel.

How Venturi Orifice Steam Traps remove Pressure Fluctuations

1. Eliminating Steam Leakage

The fundamental difference between the ECOFLOW™ venturi orifice steam trap and mechanical steam traps is their principals of their operation.  The unique design of the venturi and orifice utilises the physical properties of the difference in density between steam and condensate. This property, coupled with the phenomenon of flash formation in condensate, eliminates the possibility of steam leakage. Unlike mechanical traps, which rely on moving parts that can fail over time, venturi orifice traps operate on a fixed orifice principle. This ensures that only condensate is discharged while steam remains trapped within the system, maintaining optimal efficiency and preventing pressure fluctuations that lead to water hammer.

2. Ensuring Continuous Condensate Flow

Mechanical steam traps discharge condensate in waves due to their opening and closing sealing faces. This intermittent discharge results in a variable flow rate, which can cause sudden pressure changes and increase the risk of water hammer. By contrast, the ECOFLOW™ venturi orifice steam trap discharges condensate continuously. This steady outflow minimizes sudden pressure changes, ensuring a more stable and predictable system operation, reducing wear and tear on piping and equipment.

3. Preventing Condensate Backup

Another critical factor in water hammer prevention is the proper drainage of condensate. If condensate is not effectively removed, it can accumulate in low points of the piping system, creating conditions for severe pressure surges when steam re-boils the trapped condensate causing high-velocity movement due to expansion. Venturi orifice steam traps facilitate a continuous and efficient drainage process, preventing condensate buildup and reducing the likelihood of sudden pressure fluctuations.

The Consequences of Water Hammer 

Water hammer can have catastrophic effects on a steam system, including:

• Mechanical Damage: Pipe ruptures, valve failures and damaged heat exchangers.
• System Inefficiencies: Reduced steam flow, disrupted heat transfer and increased energy waste.
• Safety Risks: High-pressure steam or hot condensate leaks posing burn hazards to personnel.
• Operational Downtime: Unscheduled maintenance, production stoppages and increased repair costs.

By implementing ECOFLOW™ venturi orifice steam traps, operators of steam systems can significantly reduce the risk of water hammer, improve system efficiency and enhance overall safety. The elimination of steam leakage, continuous condensate discharge and prevention of condensate backup ensure a more stable and reliable steam system, ultimately leading to better performance and cost savings.