The K&H ECRS – “No Steam Traps”

K&H Energy Systems Electronic Condensate Return System (ECRS) provides the continuous-flow condensate drainage of the orifice-type systems but improves on them by eliminating any steam loss, allowing rapid system startup, and continuous purging of non-condensable gases. The ECRS also supports widely varying condensate loads and, as a computerized system, provides a platform for integrated measurement, monitoring, communication and control.


Figure 1.

Figure 1 shows a schematic diagram of a typical ECRS. Rather than using a single type of device (a “steam trap”) to carry out the condensate return functions, the ECRS typically uses two types of devices. The first is a simple orifice-type device, either with a fixed or variable opening (manual or automatic). These are placed in close proximity to steam-users, replacing a conventional trap (in some low-pressure systems, the orifice-type devices may not be required). The orifice-type devices create a pressure differential to force steam to give up its latent heat in the steam user, and allow condensate to flow continuously to the return lines. A second device, the Electronic Condensate Controller (ECC), is placed downstream from the orifice devices.


Figure 2.

Figure 2 shows a schematic of the ECC unit. The ECC may receive condensate from many steam users, but is designed to allow no steam to pass to its discharge line. Any steam that passes the orifice devices is blocked by the ECC. The ECC also releases non-condensable gases and provides an air-purge mechanism to support rapid system startup. The ECRS can be configured to accommodate steam-users with different input steam pressures by using variable orifices at the steam users. Adjusting these to achieve a common downstream pressure allows them to share a common return line.

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