Clean steam is the difference between rated output and repeat downtime.

Yes. Every separator internal is engineered to the specific reservoir's flow rate, pressure, temperature, moisture loading, and solids concentration rather than pulled from a standard catalog, because geothermal reservoirs vary significantly and change over the life of the field. Sizing is based on actual or projected wellhead conditions, not generic assumptions.

Every separator we design is backed by CFD study data. Our standard sizing program uses that data to confirm the required vane open area for your specific operating flow conditions, so CFD-informed design is built into the standard engineering process at no additional cost. For custom or retrofit projects, particularly where existing vessel geometry constrains the internals, we also offer project-specific CFD modeling and flow analysis as an optional add-on to further validate separation efficiency and pressure drop before fabrication. Whether that additional study is included or quoted separately depends on the complexity of the project.

It comes down to how the solids are behaving in the flow, along with your space and footprint constraints. If incoming solids are encapsulated within liquid droplets, a vane-type separator is typically the right fit. If there are free, suspended solids at the inlet nozzle, cyclonic internals are usually the better choice. Both technologies handle high liquid loading well. Vane separators tend to be favored where liquid loading is high, large slugs are expected, or a lower-cost, low-pressure-drop, high-turndown solution is needed in a smaller footprint, while cyclone (centrifugal) separation is favored where fine droplet removal at high efficiency is the priority.

Yes, we provide performance warranties, not just design targets. Terms are customized to the specific project's requirements and design conditions, with agreed-upon performance criteria defined on a project-by-project basis. We offer both overall performance guarantees and micron-level efficiency guarantees. For commercial steam drum applications, for example, we base performance guarantees on total dissolved solids (TDS, in ppm) in the boiler water, referencing ABMA boiler feedwater guidelines by operating pressure, and guarantee TDS levels at the outlet steam nozzle. On the micron side, we guarantee 100% removal of particles 8 to 10 microns and larger.

Often, yes, but it depends on the scope of work. In many retrofit projects, existing supports and nozzles can be reused, which avoids triggering a full re-certification under NBIC rules. If the retrofit requires welding to the vessel shell or adding new nozzles, that work falls under repair and alteration codes and may require re-registration. A qualified engineer reviews the specific vessel and scope up front, so operators know which path they're on before work begins.

Retrofit internals are specifically designed to be installed during standard planned outages rather than requiring dedicated extended downtime. Because the goal is typically to reuse the existing vessel and avoid full replacement, the scope of field work, cleaning, access through the manway, and installing new internals, is planned to fit inside a normal maintenance outage window. Actual duration still depends on vessel size, access, and whether any welding is required.

We'll want to review all available drawings of the vessel to support our analysis. That review happens during the quote stage. If the existing vessel or nozzles aren't sufficient to handle the new operating flow conditions, we'll flag that up front before moving forward.