Condensed water recovery processing unit with leakage early warning and digitization functions

Abstract

The invention relates to the technical field of condensed water treatment, and discloses a digitalized condensed water recovery treatment unit with leakage early warning, which comprises a condensed water tank, a plurality of condensed water inlets, a pressure gauge assembly, a pressure transmitter assembly, a temperature transmitter, a remote liquid level meter and a water-water heat exchanger, a steam injection pipe is arranged at the top of the steam injection pipe, and a steam flow meter, a regulating valve and a check valve are arranged on the steam injection pipe; the steam drain valves are provided with steam ultrasonic leakage detection devices; a water pump; the PLC control cabinet receives data of the sensor; the steam leakage condition is recognized, and early warning is given out; based on the flow data of the injected steam and the outgoing condensed water, whether a heat energy overload state exists or not is judged in real time; the steam adjusting valve and the water-water heat exchanger temperature control adjusting valve are adjusted in a linkage mode, and a water pump is controlled to start and stop. The problems that in the prior art, energy consumption is high, leakage is uncontrollable, and heat loads are unbalanced are solved.

Description

Technical Field

[0001] The present invention relates to the technical field of condensate treatment, in particular to a condensate recovery and treatment unit with leakage early warning and digitization. Background Art

[0002] Condensate recovery systems are a key component of industrial steam energy management and are widely used in energy-intensive industries such as petrochemicals, power generation, metallurgy, and pharmaceuticals. Their fundamental principle is to recycle condensate with high secondary utilization value back into boilers or other heat-using equipment, thereby improving system energy efficiency, reducing water waste, and lowering operating costs. In traditional closed-loop recovery systems, condensate is typically directed through a steam trap into a storage tank, where it is recovered to a certain degree of heat energy through a heat exchanger or ejector before being pumped to the target system.

[0003] However, existing condensate recovery technology still faces several challenges in practical engineering applications. For example, conventional recovery units are generally designed for fixed pressure ranges. Once high-, medium-, and low-pressure condensate enters the same system, cooling water or pressure reduction measures are often required to force the tank pressure balance, resulting in energy loss and increased equipment load. Due to the large number of front-end steam traps and their complex operating conditions, if a single trap leaks, the leaked steam will be introduced into the recovery system along with the condensate, causing system overload, abnormal tank pressure, and even forced release to the air through a safety valve or exhaust pipe, resulting in energy waste and operational hazards. Most existing recovery equipment lacks the ability to identify and intelligently respond to steam leaks, preventing early warning and intervention. Relying solely on set temperature or liquid level thresholds for on-off control fails to achieve real-time dynamic matching of the ejected steam enthalpy with the condensate's heat absorption capacity, making it difficult to determine whether the system is experiencing thermal overload. This can easily lead to thermal shock in the heat exchanger, abnormal pump startup and shutdown, or control instability.

[0004] Therefore, it is necessary to design a condensate recovery and treatment unit with leakage warning and digitalization to solve the problems existing in current technology. Summary of the Invention

[0005] In view of this, the present invention proposes a condensate recovery and treatment unit with leakage warning and digitization, aiming to solve the problems of insufficient unified recovery and control capabilities for condensate of multiple pressure levels, lack of steam leakage identification and treatment capabilities, and lack of intelligent control mechanism.

[0006] The present invention proposes a condensate recovery and treatment unit with leakage warning and digitalization, comprising:

[0007] A condensate tank is provided with a high-pressure condensate inlet, a medium-pressure condensate inlet and a low-pressure condensate inlet. The condensate tank is provided with a pressure gauge assembly, a pressure transmitter assembly, a temperature transmitter and a remote liquid level gauge for monitoring the pressure, temperature and liquid level information inside the condensate tank. A water-water heat exchanger with a baffle is provided inside the condensate tank. The outlet of the condensate tank is connected to a built-in diversion and pressurizing device. A steam ejector is provided on the top of the condensate tank. A steam flow meter, a regulating valve and a check valve are provided on the steam ejector, and the check valve is connected to the ejected port of the steam ejector;

[0008] The cooling water outlet of the water-water heat exchanger is connected to a temperature control valve, and the cooling water inlet is provided with a control butterfly valve;

[0009] A plurality of steam traps, each of which is provided with a steam ultrasonic leak detection device, wherein the steam ultrasonic leak detection device transmits a signal wirelessly;

[0010] At least two water pumps are provided, the water pumps are connected to the outlet of the built-in diversion and boosting device and lead to the steam ejector through a pipeline; the outlet of the steam ejector is connected to the condensate output pipe and is provided with a flow meter;

[0011] The PLC control cabinet is configured to receive data from sensors, including steam traps, pressure transmitters, temperature transmitters, liquid level gauges, and flow meters. The PLC control cabinet is also configured to identify steam leaks and issue early warnings. Based on the flow data of the ejected steam and the exported condensate, it determines in real time whether the system is in a thermal overload state. It also regulates the steam regulating valve and the water-to-water heat exchanger temperature control valve in a coordinated manner, and controls the start and stop of the water pump.

[0012] Furthermore, it also includes: the steam ejector is provided with a stop valve, and the stop valve is used to cut off the ejection channel.

[0013] Furthermore, two flow meters are provided, which are installed at the inlet and condensate outlet of the steam ejector respectively, for collecting ejection and output flow data in real time.

[0014] Furthermore, when the PLC control cabinet identifies a steam leak and issues an early warning, it includes:

[0015] The PLC control cabinet receives a wireless signal sent by a steam trap equipped with a steam ultrasonic leak detection device, wherein the wireless signal includes the current temperature, pressure, ultrasonic frequency amplitude and frequency energy spectrum of the steam trap;

[0016] Performing spectrum analysis on the wireless signal to extract high-frequency noise characteristic factors, transient peak changes, and frequency domain energy parameters compared with standard thresholds;

[0017] Based on the leakage pattern database, it identifies whether there is a leakage state, and issues a leakage warning when the identification result meets the leakage threshold condition.

[0018] Furthermore, the PLC control cabinet determines in real time whether the system is in a heat energy overload state based on the flow data of the injected steam and the external condensate, including:

[0019] The PLC control cabinet obtains data from the steam flow meter on the steam ejector pipe and a built-in steam enthalpy database, and obtains the enthalpy load of the ejected steam according to the steam pressure and temperature;

[0020] Obtain data from the condensate output flow meter and temperature transmitter, and combine this with the specific heat capacity of water to obtain the heat carrying capacity of the outlet condensate;

[0021] The ratio data of the thermal enthalpy load and the heat carrying capacity is obtained. When the ratio data exceeds 1 and the ratio data is greater than the upper limit of the heat exchanger load, the PLC control cabinet determines that a thermal energy overload state exists.

[0022] Furthermore, when the PLC control cabinet determines that a thermal overload state exists, the process includes:

[0023] The PLC control cabinet controls the steam regulating valve to reduce its opening, thereby reducing the ejected steam flow rate; links the water-water heat exchanger cooling water temperature control valve to increase the cooling water flow rate; controls the start and stop of the standby water pump, switching to a dual-pump operation mode; and issues a thermal energy overload alarm signal.

[0024] Furthermore, the PLC control cabinet is also provided with a thermal energy overload prediction model based on historical operating data. The thermal energy overload prediction model is based on a vector regression algorithm, and is learned according to the steam injection volume, condensate temperature and outlet pressure data in multiple historical cycles, and issues an impending overload warning when a new round of flow increases.

[0025] Furthermore, when the PLC control cabinet jointly regulates the steam regulating valve and the water-water heat exchanger temperature control valve, it includes:

[0026] When the PLC control cabinet determines that there is a thermal overload or is about to be overloaded, it adjusts the opening of the steam regulating valve through proportional-integral control logic, and adjusts the steam flow rate using the change speed of the induced steam flow rate as a feedback parameter.

[0027] Furthermore, when the PLC control cabinet jointly adjusts the temperature control valve of the water-water heat exchanger, it includes: based on temperature-flow dynamic matching, the cooling water flow rate increases as the condensate outlet temperature increases.

[0028] Furthermore, when the PLC control cabinet determines that a thermal overload state exists, the PLC control cabinet further includes:

[0029] Before executing the steam regulating valve, water-water heat exchanger temperature control valve and water pump control operations, the PLC control cabinet dynamically determines the optimal execution strategy order based on the change rate of each monitoring parameter under the current operating state, where:

[0030] If the rate of change of the injected steam flow rate is higher than the first threshold, the steam regulating valve control is performed first;

[0031] If the rising rate of the condensate outlet temperature is higher than the second threshold, the temperature control valve is adjusted first;

[0032] If the rate of drop of the liquid level in the tank is higher than the set limit, the standby water pump will be started first and switched to dual pump mode.

[0033] Compared with the existing technology, the beneficial effect of the present invention is that by constructing an integrated condensate recovery and treatment unit with multi-stage condensate adaptability, steam leakage warning mechanism and thermal energy dynamic regulation function, the problems of high energy consumption, uncontrollable leakage and unbalanced heat load existing in traditional technology are overcome. By installing independent high-, medium-, and low-pressure condensate inlets on the condensate tank and comprehensive pressure, temperature, and level monitoring components, the system achieves unified condensate recovery from multiple sources and dynamic operating condition identification. An internally integrated water-to-water heat exchanger with baffles and a diversion and boosting device improves heat exchange efficiency and flow stability. A controllable steam heat recovery channel is constructed by installing a steam ejector and its associated ejector, flowmeter, and regulating valve components. A wireless steam leak detection device is deployed at the steam trap end, combined with the signal reception and early warning capabilities of the PLC control cabinet, to achieve real-time identification and response to steam leaks. Based on a dynamic comparison of the steam ejection volume with the outgoing condensate flow and temperature, the system determines the heat load status in real time and automatically adjusts the steam valve, temperature control valve, and water pump operating strategies to ensure system thermal balance and efficient operation. This improves the safety, stability, and energy efficiency of the condensate recovery system under complex operating conditions. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Various other advantages and benefits will become apparent to those skilled in the art upon reading the detailed description of the preferred embodiment below. The accompanying drawings are for illustration purposes only and are not to be considered as limiting the present invention. The same reference symbols are used throughout the drawings to represent the same components. In the drawings:

[0035] Figure 1 A schematic diagram of the upper structural portion of a condensate recovery unit with leakage warning and digitization provided in an embodiment of the present invention;

[0036] Figure 2 A schematic diagram of the lower half of the structure of a condensate recovery and treatment unit with leakage warning and digitization provided in an embodiment of the present invention.

[0037] Among them, 1. Condensate outlet; 2. Gate valve; 3. Steam ejector; 4. Stop valve; 7. Check valve; 10. Pressure gauge assembly; 11. Water pump PA; 12. Water pump PB; 16. Drain valve; 17. Air release valve; 18. Diversion and pressurization device; 19. Drainage collection outlet; 20. Water-water heat exchanger; 21. Control butterfly valve; 22. Heat exchanger circulating water inlet; 23. Heat exchanger circulating water outlet; 24. Temperature control valve; 2 5. Temperature transmitter; 26. Local thermometer; 27. Safety valve; 28. High-pressure steam trap; 29. ​​Medium-pressure steam trap; 30. Low-pressure steam trap; 31. Low-pressure condensate inlet; 32. Medium-pressure condensate inlet; 33. High-pressure condensate inlet; 35. Pressure transmitter assembly; 36. Condensate tank; 38. Remote liquid level gauge; 40. PLC control cabinet; 41. Steam flow meter; 42. Steam regulating valve; 44. Flow meter. DETAILED DESCRIPTION

[0038] Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. Although exemplary embodiments of the present disclosure are shown in the accompanying drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments set forth herein. On the contrary, these embodiments are provided to enable a more thorough understanding of the present disclosure and to fully convey the scope of the present disclosure to those skilled in the art. It should be noted that, unless there is a conflict, the embodiments of the present disclosure and the features in the embodiments can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in conjunction with the embodiments.

[0039] In traditional condensate recovery systems, the mixed input of condensate from multiple pressure zones causes pressure fluctuations within the tank, requiring external cooling or pressure reduction intervention, resulting in energy loss and increased equipment load. The lack of leak detection in the front-end steam trap allows steam to mix with the condensate, causing system enthalpy overload and unreliable real-time identification. The existing control logic relies solely on fixed threshold adjustments and is unable to dynamically match the heat load of the injected steam with the heat carrying capacity of the condensate, leading to the risk of thermal shock in the heat exchanger and pump control instability.

[0040] For example, a condensate recovery system is equipped with three inlets: high, medium, and low pressure. The pressure balance in the tank needs to be achieved by adjusting the cooling water flow and manually intervening in the pressure reducing valve. When the proportion of high-pressure condensate suddenly increases, the tank pressure rises rapidly, triggering the safety valve to release pressure. At the same time, the cooling water flow is forced to increase to maintain the tank temperature. A valve in the steam trap group fails to seal and leaks steam. The leaked steam enters the tank along with the condensate. The abnormal fluctuation of the tank pressure exceeds the threshold of the pressure transmitter, and the system automatically switches to the emptying mode. At this time, the induced steam flow rate and the condensate output flow rate are not matched in real time. The sudden increase in the inlet temperature of the heat exchanger causes thermal stress concentration in the tube bundle, and the water pump starts and stops frequently due to liquid level fluctuations.

[0041] If these issues are not addressed, the system will remain in a state of prolonged imbalance between pressure and heat load, exacerbating energy loss and shortening the life of critical equipment. Undetected steam leaks can lead to tank overpressure and increase the frequency of unintended safety valve activation. Accumulated thermal shock in heat exchangers can cause tube bundle deformation or weld cracking, leading to media leaks. Abnormal pump startup and shutdown not only reduces pumping efficiency but can also cause motor overload and damage. System control instability necessitates increased manual intervention, increasing operational costs and complexity.

[0042] For this, see Figure 1-2 As shown, the present application proposes a condensate recovery and treatment unit with leakage warning and digitization, including: a condensate tank 36, provided with a high-pressure condensate inlet 33, a medium-pressure condensate inlet 32 ​​and a low-pressure condensate inlet 31, and the high-pressure condensate inlet 33 is provided with a high-pressure steam trap 28, the medium-pressure condensate inlet 32 ​​is provided with a medium-pressure steam trap 29, and the low-pressure condensate inlet 31 is provided with a low-pressure steam trap 30. The condensate tank 36 is provided with a pressure gauge assembly 10, a pressure transmitter assembly 35, a temperature transmitter 25, and a remote liquid level gauge 38 for monitoring the tank pressure, temperature and liquid level information of the condensate tank 36. A water-water heat exchanger 20 with a baffle is provided inside the condensate tank 36, and the water-water heat exchanger 20 is provided with a heat exchanger circulating water inlet 22 and a heat exchanger circulating water outlet 23. The outlet of the condensate tank 36 is connected to the built-in diversion and boosting device 18. A steam ejector is installed at the top of the condensate tank 36. This ejector is equipped with a steam flowmeter 41, a regulating valve, and a check valve 7. The check valve 7 is connected to the ejected port of the steam ejector 3. The cooling water outlet of the water-to-water heat exchanger 20 is connected to a temperature-controlled regulating valve 24, and the cooling water inlet is equipped with a control butterfly valve 21. Several steam traps are provided, each equipped with a steam ultrasonic leak detection device that transmits signals wirelessly. At least two water pumps are provided, connected to the outlet of the built-in diversion and boosting device 18 and connected to the steam ejector 3 via a pipeline. The outlet of the steam ejector 3 is connected to the condensate output pipeline and is equipped with a flowmeter 44. A PLC control cabinet 40 is configured to receive data from sensors, including the steam trap, pressure transmitter, temperature transmitter 25, liquid level meter, and flowmeter 44. The PLC control cabinet 40 is also configured to identify steam leaks and issue warnings. Based on the flow rate data of the injected steam and the condensate being sent out, it determines in real time whether the system is experiencing a thermal overload. This system then coordinates the steam regulating valve 42 and the temperature control valve 24 of the water-to-water heat exchanger 20, as well as controls the start and stop of the water pump.

[0043] Specifically, an embodiment of the present application designs a high-pressure steam trap with a steam ultrasonic leak detection function that can transmit wireless signals, a medium-pressure steam trap with a steam ultrasonic leak detection function that can transmit wireless signals, and a low-pressure steam trap with a steam ultrasonic leak detection function that can transmit wireless signals. Each set of signals is wirelessly transmitted to a PLC control cabinet 40 with wireless transceiver signals. A low-pressure steam condensate inlet, a medium-pressure steam condensate inlet, and a high-pressure steam condensate inlet are provided on the condensate tank 36. A safety valve 27, a pressure gauge assembly 10, and a pressure transmitter assembly 35 are installed. The pressure transmitter signal is transmitted to the PLC control cabinet 40 with wireless transceiver signals, and a remote transmission system is installed on the side. Liquid level meter 38, liquid level meter gate valve 2 and liquid level meter gate valve 2 are installed at both ends of the remote liquid level meter 38, the signal of the remote liquid level meter 38 is transmitted to the PLC control cabinet 40 with wireless signal transmission and reception, an on-site thermometer 26 and a temperature transmitter 25 are installed at the liquid phase of the condensate tank 36, the signal of the temperature transmitter 25 is transmitted to the PLC control cabinet 40 with wireless signal transmission and reception, a water-to-water heat exchanger with a baffle is designed and installed in the condensate tank 36, the outlet of the water-to-water heat exchanger is installed with a built-in diversion and boosting device 18, a temperature control regulating valve 24 is installed at the cooling water outlet of the water-to-water heat exchanger, the signal line of the temperature control valve is connected to the PLC control cabinet 40 with wireless signal transmission and reception, the cooling water inlet of the water-to-water heat exchanger is installed with a Control butterfly valve 21, an exhaust pipe is installed at the top of the condensate tank 36, the exhaust pipe leads to the bottom and is equipped with a bleed valve 17 connected to the sewage collection port 19, a sewage valve 16 is installed under the condensate tank 36 and connected to the sewage collection port 19, the built-in diversion and boosting device 18 is composed of a multi-layer partition and a cover plate, the outlet of the built-in diversion and boosting device 18 leads to the water pump P-A11 and the water pump P-B12, and the inlet gate valve 2 and the inlet gate valve 2 are respectively installed in front of the two water pump inlets, the outlet of the water pump P-A11 is connected to the check valve 7 and the gate valve 2, and then leads to the inlet gate valve 2 of the steam ejector 3, a pressure gauge assembly 10 is installed on the outlet pipe of the water pump P-A11, the water pump P-A11 The motor is connected to a PLC control cabinet 40 with wireless signal transmission and reception. The outlet of the water pump P-B12 is connected to a check valve 7 and a gate valve 2, and then leads to the inlet gate valve 2 of the steam ejector 3. A pressure gauge assembly 10 is installed in the outlet pipe of the water pump P-B12. The motor of the water pump P-B12 is connected to a PLC control cabinet 4040 with wireless signal transmission and reception. A steam ejector pipe is installed on the top of the condensate tank 36. The steam ejector pipe passes through the bottom and is equipped with a steam flowmeter 41, a regulating valve, and a check valve 7. The check valve 7 is connected to the ejected port of the steam ejector 3. The steam ejector 3 is provided with a bypass stop valve 4. The outlet of the steam ejector 3 is connected to the gate valve 2, and the gate valve 2 is connected to the flowmeter 44 and the condensate outlet 1.

[0044] Specifically, since there are multiple pressure gauge assemblies 10, multiple stop valves 7 and multiple gate valves 2 in the drawings, the same functional structures are numbered because their functions are the same.

[0045] Specifically, the high-pressure condensate inlet 33, the medium-pressure condensate inlet 32, and the low-pressure condensate inlet 31 are interfaces for the condensate tank 36 to receive condensate of different pressure levels. Specifically, they can be connected using branch pipes and pressure adapter flanges to achieve compatible input of condensate from multiple pressure ranges, avoiding pressure imbalances within the tank caused by the mixing of condensate of different pressures in traditional systems. The pressure gauge assembly 10, the pressure transmitter assembly 35, the temperature transmitter 25, and the remote level gauge 38 are monitoring devices used to collect real-time pressure, temperature, and liquid level data within the tank. Specifically, they can use pressure sensors, thermocouples, radar level gauges, and other devices. Through continuous monitoring, they ensure that tank operating parameters remain within safe thresholds. The water-to-water heat exchanger 20 with baffles is a shell-and-tube heat exchange structure arranged within the condensate tank 36. Specifically, it can use corrugated plates or spiral baffles. This design enhances fluid turbulence to improve heat exchange efficiency while preventing excessive condensate temperature within the tank. The built-in flow guide and booster device 18 refers to a fluid guiding mechanism installed at the outlet of the condensate tank 36. Specifically, it can adopt a multi-stage centrifugal impeller or a deflector cover structure. By optimizing the flow path, it reduces the risk of cavitation and improves pumping efficiency. The steam flowmeter 41, regulating valve, and check valve 7 installed on the steam ejector pipe refer to components used to control the ejected steam flow rate. Specifically, they can adopt a flowmeter 44, an electric regulating valve, and a spring-loaded check valve 7. The steam ejection volume is precisely controlled by adjusting the valve opening. The check valve 7 prevents backflow of the medium. The steam ultrasonic leak detection device refers to an acoustic signal acquisition module installed at the steam trap. Specifically, it can adopt a piezoelectric ultrasonic sensor. It detects internal valve leaks by capturing high-frequency acoustic signals and transmits data wirelessly to avoid wiring interference. The at least two water pumps refer to a parallel configuration of centrifugal pumps. Specifically, they can adopt a one-in-use, one-in-standby or alternating operation mode. Redundancy ensures continuous system operation in the event of a single pump failure. Among them, the PLC control cabinet 40 receives sensor data and links to adjust valves and water pumps, which refers to an automation system based on a programmable logic controller. Specifically, it can adopt industrial-grade PLC modules and communication protocols to dynamically adjust the equipment operating status through real-time analysis of pressure, temperature, and flow parameters to prevent thermal overload.

[0046] The core innovation of this application lies in the coordinated design of a multi-pressure condensate inlet and a built-in diversion and boosting device 18, enabling the non-interventional mixed recovery of condensate at different pressures. This system, combined with a steam ultrasonic leak detection device and dynamic data analysis from a PLC control cabinet 40, identifies steam trap leaks in real time and issues warnings. Based on flow and enthalpy matching calculations between the ejected steam and the delivered condensate, the steam regulating valve 42, the temperature control valve of the water-to-water heat exchanger 20, and the water pump are all coordinated to ensure a dynamic balance between the system's heat load and cooling capacity.

[0047] The working process and principle of the present application are as follows: the condensate tank 36 is provided with high-pressure, medium-pressure and low-pressure condensate inlets 31 to realize the mixed input of condensate from multiple pressure sections. The condensate tank 36 is installed with a pressure gauge assembly 10, a pressure transmitter assembly 35, a temperature transmitter 25 and a remote level gauge 38 for comprehensively monitoring the pressure, temperature and liquid level information in the tank. A water-water heat exchanger 20 with a baffle is provided in the tank to achieve pressure self-balancing through the internal heat exchange structure. The tank outlet is connected to a built-in diversion and boosting device 18 to increase the outlet pressure. A steam flow meter 41, a regulating valve and a check valve 7 are provided on the steam ejector pipe at the top of the tank. The check valve 7 is connected to the ejected port of the steam ejector 3 to eject steam and prevent backflow.

[0048] The cooling water outlet of the water-to-water heat exchanger 20 is connected to a temperature-controlled regulating valve 24, and the inlet is equipped with a control butterfly valve 21 to regulate the cooling water flow. Several steam traps are equipped with steam ultrasonic leak detection devices, which transmit leak signals wirelessly. At least two water pumps are connected to the outlet of the built-in diversion and boosting device 18 and are connected to the steam ejector 3 via piping. The outlet of the steam ejector 3 is connected to the condensate output pipeline and is equipped with a flow meter 44.

[0049] The PLC control cabinet 40 receives data from various sensors, including information from the steam trap, pressure transmitter, temperature transmitter 25, liquid level meter, and flowmeter 44. The PLC control cabinet 40 analyzes ultrasonic signals from the steam trap to identify steam leaks and issue warnings. Based on the flow rate data of ejected steam and condensate, the PLC control cabinet 40 determines in real time whether the system is experiencing thermal overload. Based on this determination, the PLC control cabinet 40 coordinates and adjusts the steam regulating valve 42 and the temperature control valve 24 of the water-to-water heat exchanger 20, and also controls the start and stop of the water pump to maintain system thermal balance.

[0050] As a preferred embodiment, the solution of this application is specifically implemented as follows: The condensate tank 36 adopts a vertical cylindrical structure, with three condensate inlets at the top: high-pressure, medium-pressure, and low-pressure, respectively, for receiving condensate at different pressure ranges. A pressure gauge assembly 10, a pressure transmitter assembly 35, a temperature transmitter 25, and a remote level gauge 38 are mounted on the tank's outer wall. The water-to-water heat exchanger 20 within the tank adopts a shell-and-tube structure, with baffles arranged in a spiral pattern to enhance heat exchange. The internal diversion and pressurization device 18 adopts a Venturi tube structure and is installed at the bottom outlet of the tank.

[0051] A steam ejector is installed at the tank roof, equipped with a steam flowmeter 41, a regulating valve, and a check valve 7. The cooling water outlet of the water-to-water heat exchanger 20 is connected to an electric temperature-controlled regulating valve 24, and an electric control butterfly valve 21 is installed at the inlet. The steam traps utilize a thermodynamic structure, with an ultrasonic sensor installed on the outside of each trap, which transmits detection signals via a wireless module.

[0052] The water pump is a vertical multi-stage centrifugal pump, with one pump in use and one in standby. The pump outlet is connected via a pipeline to the power nozzle of steam ejector 3. Steam ejector 3 is a single-stage steam jet pump, with its outlet connected to the condensate output pipe and equipped with an electromagnetic flowmeter 44.

[0053] The PLC control cabinet 40 utilizes a modular structure, comprising a data acquisition module, a signal processing module, a control output module, and a human-machine interface. The control cabinet communicates with sensors and actuators via industrial Ethernet. The PLC program includes a steam leak detection algorithm, a thermal energy balance calculation module, and linkage control logic.

[0054] During system operation, condensate from multiple pressure zones enters the tank, undergoes internal heat exchange and pressure balancing, and is then pumped out by a water pump. The PLC control cabinet 40 monitors various parameters in real time and issues a warning signal when a steam trap leak is detected. Based on the flow data of ejected steam and output condensate, the control cabinet determines the thermal load status and adjusts the steam valve opening, heat exchanger cooling water flow, and water pump operation mode accordingly to maintain stable system operation.

[0055] Through the above scheme, the present application realizes the automatic pressure balance of condensate in multiple pressure sections, avoids external cooling or pressure reduction intervention, and reduces energy loss. The real-time leakage detection function of the steam trap enables the system to promptly identify and warn of steam leakage problems, preventing steam from mixing into the condensate and causing the system's thermal enthalpy overload. The thermal energy balance judgment and linkage adjustment mechanism based on real-time flow data enables the system to dynamically match the heat load of the induced steam with the heat carrying capacity of the condensate, effectively avoiding the risk of thermal shock in the heat exchanger and the problem of water pump control instability. These improvements improve the operational stability and energy utilization efficiency of the condensate recovery system, and reduce equipment failure rate and maintenance costs.

[0056] In some of the above-mentioned schemes of the present application, the steam ejector 3 controls the ejected steam flow rate through a regulating valve. However, when an abnormal operating condition occurs in the system, the ejection channel cannot be completely blocked by relying solely on the regulating valve, which may cause steam to continue to enter the condensate tank 36, exacerbating the risk of thermal overload or expanding the scope of leakage impact.

[0057] The present application further proposes that the steam ejector 3 is provided with a stop valve 4, which is used to cut off the ejection channel.

[0058] The shutoff valve 4 is installed at the inlet or outlet of the steam ejector 3's ejector channel. Its valve body is secured to the pipeline using a flange or threaded connection. The shutoff valve 4 is opened and closed by a pneumatic or electric actuator, which is connected to the PLC control cabinet 40 via a signal line. When the ejector channel needs to be completely blocked, the valve core of the shutoff valve 4 moves along its axial direction to the fully closed position, forming a physical isolation barrier.

[0059] Specifically, after the PLC control cabinet 40 identifies a steam leak or thermal overload state, it sends a closing command to the stop valve 4. The actuator drives the valve core to move, so that the flow cross-section of the ejection channel is completely closed, blocking the steam flow path. At this time, the steam ejector 3 stops working, and the pressure fluctuations in the condensate tank 36 are limited to a controllable range. For example, when a leak in the steam trap is detected, causing the pressure in the tank to exceed the safety threshold, the closure of the stop valve 4 can prevent external steam from continuously entering the tank body, avoiding the tripping of the safety valve 27 or the backflow of condensate. Furthermore, the closed state of the stop valve 4 is fed back to the PLC control cabinet 40 through the position sensor to ensure the reliability of the execution action. After the system returns to normal operating conditions, the stop valve 4 is reopened, and the ejection channel resumes the steam ejection function.

[0060] As a preferred embodiment, the solution of the present application is specifically implemented as follows: the steam ejector 3 is provided with a stop valve 4, which is used to cut off the ejection channel. Specifically, the stop valve 4 is installed at the inlet of the steam ejector 3 and adopts a manual ball valve structure. Under normal operating conditions, the stop valve 4 remains fully open, allowing the ejected steam to flow freely into the ejector. When equipment maintenance or system overhaul is required, the operator can close the ball valve by rotating the handle of the stop valve 4, thereby completely cutting off the steam ejection channel. This design allows the steam ejector 3 to be isolated for overhaul or replacement without affecting the operation of the entire condensate recovery system.

[0061] Through the above-mentioned technical solution, the present application achieves flexible control and isolation of steam ejector 3. Thus, when the system requires maintenance or encounters an abnormal situation, steam ejection can be quickly shut off, preventing the continued entry of steam into the system, which could cause unnecessary energy loss or safety hazards. Furthermore, the provision of shut-off valve 4 also provides the system with greater operational flexibility, allowing the steam ejection to be adjusted or shut off as needed under different operating conditions, thereby optimizing system operating efficiency.

[0062] In some of the aforementioned solutions of this application, the condensate recovery unit is connected to the condensate output pipeline via a steam ejector 3 . Real-time flow data of the ejected steam and the condensate being delivered is required to determine the thermal overload condition. However, if data is collected using only a single flowmeter 44 , it is impossible to distinguish between the dynamic changes in the ejected flow rate and the output flow rate, resulting in errors in the calculation of the thermal enthalpy load and heat carrying capacity, thereby affecting the accuracy of the overload determination.

[0063] The present application further proposes that two flow meters 44 are provided, which are installed at the inlet of the steam ejector 3 and the condensate outlet 1 respectively, for collecting the ejection and output flow data in real time.

[0064] Among them, the inlet flow meter 44 is installed at the inlet pipe section of the steam ejector 3 to measure the actual flow of the ejected steam. The outlet flow meter 44 is installed at the end of the condensate output pipe to monitor the instantaneous flow of the condensate being sent out. The two flow meters 44 adopt a split installation structure to independently collect the flow signals of the inlet and outlet respectively, and synchronize the data to the PLC control cabinet 40 through wired or wireless transmission. The inlet flow meter 44 and the outlet flow meter 44 use electromagnetic or ultrasonic flow sensors with the same range to ensure the synchronization and consistency of data collection. The installation position of the inlet flow meter 44 is no more than 5 times the pipe diameter away from the inlet flange of the steam ejector 3, and the length of the straight pipe section downstream of the elbow of the condensate output pipe from the outlet flow meter 44 is no less than 10 times the pipe diameter to meet the flow measurement accuracy requirements.

[0065] Specifically, the flowmeter 44 at the steam ejector 3 inlet collects real-time flow data of the ejected steam. This data, combined with the pressure-temperature parameters in the steam enthalpy database, accurately calculates the enthalpy load of the ejected steam. The flowmeter 44 at the condensate outlet 1 simultaneously collects flow data of the outgoing condensate. Combined with the outlet temperature measured by the temperature transmitter 25, the real-time heat carrying capacity of the condensate is calculated using the water specific heat capacity formula. The data from the two flowmeters 44 are aligned with the timestamps and input into the PLC control cabinet 40, which calculates the ratio of the enthalpy load to the heat carrying capacity. When the steam ejection rate measured by the inlet flowmeter 44 increases while the condensate output rate measured by the outlet flowmeter 44 does not rise synchronously, a trend of heat energy accumulation can be determined. If the difference between the two flow rates exceeds a preset threshold and the ratio exceeds the upper limit of the heat exchanger load, an overload warning is triggered. The segmented monitoring of the flowmeter 44 eliminates flow fluctuation errors caused by single-point measurement, ensures the accuracy of the heat balance calculation, and improves the response speed and control stability of overload condition identification.

[0066] As a preferred embodiment, the solution of this application is specifically implemented as follows:

[0067] Two flowmeters 44 are installed, one at the steam ejector 3 inlet and one at the condensate outlet 1. The inlet flowmeter uses a vortex flowmeter with a measurement range of 0-10 t / h and an accuracy of ±1.5%, and is used to collect real-time ejector steam flow data. The outlet flowmeter uses an electromagnetic flowmeter with a measurement range of 0-50 t / h and an accuracy of ±0.5%, and is used to collect real-time condensate output flow data. Both flowmeters use a 4-20mA analog signal output and are connected to the analog input module of the PLC control cabinet 40. The PLC control cabinet 40 collects real-time data from the two flowmeters to calculate the ejection ratio and determine the system operating status.

[0068] Through the above-mentioned technical solution, this application achieves precise measurement of steam ejection and condensate output. This allows accurate calculation of the system ejection ratio, providing a basis for determining the thermal load status. Furthermore, by real-time monitoring of inlet and outlet flow rates, abnormalities such as steam leaks or insufficient condensate return can be promptly detected, helping to improve the safety and stability of system operation. Furthermore, the dual flowmeter 44 configuration provides a data foundation for system energy efficiency analysis and optimization, facilitating intelligent and refined management of condensate recovery and treatment.

[0069] In some of the above-mentioned solutions of the present application, after receiving the wireless signal from the steam trap, the PLC control cabinet 40 is unable to effectively identify the leakage status of the steam trap, resulting in an inability to timely warn of the system overload problem caused by steam leakage.

[0070] This application further proposes that a PLC control cabinet 40 receives wireless signals transmitted by a steam trap equipped with a steam ultrasonic leak detection device. The wireless signals contain the trap's current temperature, pressure, ultrasonic frequency amplitude, and frequency energy spectrum. Spectral analysis is performed on the wireless signals to extract high-frequency noise characteristic factors, transient peak changes, and frequency domain energy parameters compared to standard thresholds. Based on a leak pattern database, the system identifies the presence of a leak and, if the identification result meets the leak threshold, issues a leak warning.

[0071] The received wireless signal contains temperature, pressure, ultrasonic frequency amplitude, and frequency energy spectrum data, which are transmitted in real time to the PLC control cabinet 40 via a wireless transmission module. The spectrum analysis process uses a fast Fourier transform algorithm to decompose the signal. High-frequency noise characteristic factors are calculated by integrating the energy within a specific frequency band. Transient peak changes are detected using a sliding window to detect sudden changes in the time domain signal. The frequency domain energy parameters are compared with standard thresholds pre-stored in a leakage pattern database. These thresholds are established based on leakage test data at different pressure levels.

[0072] Specifically, the ultrasonic leak detection device of the steam trap collects operating data in real time and sends it to the PLC control cabinet 40. The PLC control cabinet 40 performs spectral decomposition on the received ultrasonic frequency signal, extracts the energy integral of the high-frequency band as the noise characteristic factor, and detects the sudden change peak in the time domain signal as a transient change indicator. By matching the extracted characteristic parameters with the threshold range under the corresponding pressure level in the leakage pattern database, if the high-frequency noise energy exceeds the threshold and the transient peak frequency reaches a preset number of times, it is determined that there is a steam leak. The PLC control cabinet 40 triggers an early warning signal based on the judgment result, and records the time, location and parameter abnormality of the leak. For example, when the steam trap is operating at a pressure of 0.8MPa, if the energy integral of the 15kHz-20kHz frequency band is detected to exceed 30% of the database threshold and more than 5 transient peaks appear per second, a leak warning is triggered.

[0073] As a preferred embodiment, the solution of this application is specifically implemented as follows:

[0074] The PLC control cabinet 40 receives wireless signals transmitted by steam traps equipped with ultrasonic steam leak detection devices. This wireless signal contains information about the trap's current temperature, pressure, ultrasonic frequency amplitude, and frequency energy spectrum. Furthermore, a spectral analysis is performed on the received wireless signal to extract high-frequency noise characteristic factors, transient peak changes, and frequency-domain energy parameters compared to standard thresholds. Specifically, the high-frequency noise characteristic factors are obtained by Fourier transforming the ultrasonic frequency amplitude, transient peak changes are determined by time-domain analysis of the ultrasonic frequency amplitude, and frequency-domain energy parameters are calculated by comparing the frequency energy spectrum with a preset standard threshold.

[0075] This allows the system to identify leaks based on a pre-established leak pattern database. This database contains characteristic parameter combinations for various typical leak scenarios. For example, the parameter ranges for normal operation, parameter variation trends for minor leaks, and parameter mutations for major leaks are examples. By matching the extracted characteristic parameters with patterns in the database, the system can determine the current operating status of the steam trap.

[0076] If the identification results meet the leakage threshold, a leak warning is issued. As a preferred embodiment, multiple leakage thresholds can be set, corresponding to different warning levels. For example, when characteristic parameters slightly deviate from the normal range, a low-level warning is issued. When characteristic parameters are significantly abnormal, a medium-level warning is issued. When characteristic parameters reach a dangerous level, a high-level warning is issued. Warning information can be released through various means, such as the control system display interface, audio and visual alarm devices, and remote monitoring terminals.

[0077] Through the above-mentioned technical solution, this application achieves real-time monitoring and intelligent identification of steam trap leakage status. Wireless transmission technology avoids the wiring difficulties and high maintenance costs of traditional wired monitoring systems. Spectral analysis is used to extract multidimensional feature parameters, improving the accuracy and reliability of leak identification. Matching and identification based on a leak pattern database gives the system adaptive capabilities to handle leaks under different operating conditions. A multi-level early warning mechanism provides timely and effective decision-making support for operations and maintenance personnel, helping to prevent potential safety hazards and energy waste.

[0078] In some of the above-mentioned schemes of the present application, it is proposed to cope with the thermal energy overload state by adjusting the opening of the steam regulating valve 42, the cooling water flow rate and the start and stop of the water pump. However, in the adjustment process, there is a lack of dynamic matching of the thermal enthalpy of the induced steam and the heat absorption capacity of the condensed water, resulting in an inability to accurately judge whether the system is in a thermal energy overload state, which may cause adjustment lag or misjudgment.

[0079] This application further proposes that the PLC control cabinet 40 acquire data from the steam flowmeter 41 on the steam ejector pipe and a built-in steam enthalpy database to determine the enthalpy load of the ejected steam based on the steam pressure and temperature. Data from the condensate output flowmeter 44 and temperature transmitter 25 are also acquired and combined with the specific heat capacity of water to determine the heat carrying capacity of the outlet condensate. The ratio of the enthalpy load to the heat carrying capacity is obtained. When the ratio exceeds 1 and is greater than the upper limit of the heat exchanger load, a thermal overload condition is determined.

[0080] The built-in steam enthalpy database stores steam enthalpy values ​​corresponding to different pressures and temperatures. The current steam state parameters are collected in real time via the steam pressure transmitter and temperature transmitter 25, and the corresponding unit mass enthalpy value is retrieved from the database. The condensate heat carrying capacity is calculated by multiplying the mass flow rate measured by the condensate output flowmeter 44 by the outlet temperature change measured by the temperature transmitter 25, and then multiplying the result by the specific heat capacity constant of water. The ratio of enthalpy load to heat carrying capacity is calculated by dividing the product of the steam mass flow rate and the unit enthalpy by the condensate heat carrying capacity. When this ratio exceeds 1 and exceeds the preset upper load limit of the heat exchanger, the overload determination logic is triggered.

[0081] Specifically, the flowmeter 44 on the steam ejector pipe collects steam mass flow in real time, while the pressure transmitter and temperature transmitter 25 transmit the current steam pressure and temperature to the PLC control cabinet 40. Based on the pressure and temperature parameters, the PLC control cabinet 40 matches the corresponding unit enthalpy value from the enthalpy database and multiplies the steam mass flow rate by the unit enthalpy to obtain the total enthalpy load. Simultaneously, the condensate output flowmeter 44 collects the condensate mass flow rate, and the temperature transmitter 25 collects the outlet temperature. Combined with the specific heat capacity of water, the heat that the condensate can absorb per unit time is calculated as the heat carrying capacity. The ratio of the enthalpy load to the heat carrying capacity is compared with a preset threshold. When the ratio exceeds 1 and exceeds the upper limit of the heat exchanger's design load, indicating that the system heat input exceeds the heat dissipation capacity of the heat exchanger and condensate, the PLC control cabinet 40 triggers an overload detection. This detection method dynamically matches heat input with heat dissipation capacity, avoiding misjudgments caused by relying solely on a single parameter and ensuring accurate overload identification.

[0082] As a preferred embodiment, the solution of this application is specifically implemented as follows:

[0083] The PLC control cabinet 40 retrieves data from the steam flowmeter 41 on the steam ejector pipe and a built-in steam enthalpy database. It calculates the enthalpy load of the ejected steam based on the steam pressure and temperature. For example, when the steam pressure is 0.5 MPa and the temperature is 150°C, the built-in database returns a corresponding enthalpy value of 2750 kJ / kg.

[0084] Furthermore, the PLC control cabinet 40 obtains data from the condensate output flowmeter 44 and the temperature transmitter 25, and combines this with the specific heat capacity of the water to calculate the heat carrying capacity of the outlet condensate. Specifically, assuming a condensate flow rate of 10 t / h, a temperature of 80°C, and a specific heat capacity of 4.2 kJ / (kg·°C), the heat carrying capacity is calculated as 10,000 kg / h × 4.2 kJ / (kg·°C) × (100°C - 80°C) = 840,000 kJ / h.

[0085] The PLC control cabinet 40 then obtains the ratio of the enthalpy load to the heat carrying capacity. When this ratio exceeds 1 and is greater than the upper limit of the heat exchanger load, the PLC control cabinet 40 determines that a thermal overload condition exists. For example, if the enthalpy load is 900,000 kJ / h, the heat carrying capacity is 840,000 kJ / h, the ratio is 1.07, and the upper limit of the heat exchanger load is 1.05, the system is determined to be in a thermal overload condition.

[0086] Through the above-mentioned technical solution, the present application achieves real-time monitoring of the condensate recovery system's thermal energy load and accurate determination of overload conditions. The PLC control cabinet 40 obtains the enthalpy load of the ejected steam and the heat carrying capacity of the outlet condensate, calculates the ratio between the two, and compares it with the upper limit of the heat exchanger load, thereby promptly identifying whether the system is in a thermal energy overload state. This dynamic judgment method based on actual operating parameters avoids the limitations of relying solely on fixed thresholds for control, improving the safety and stability of system operation. At the same time, this method provides a reliable data foundation for subsequent automatic adjustments and early warnings, helping to optimize system performance and prevent equipment damage.

[0087] In some of the above-mentioned schemes of the present application, when it is determined that a thermal energy overload state exists, it may not be possible to quickly balance the system heat load by simply adjusting the steam flow or cooling water flow rate, and if the water pump switching operation does not match the rate of change of the thermal parameters, it may cause the liquid level fluctuation in the tank to intensify or the equipment response to lag.

[0088] The present application further proposes to control the opening of the steam regulating valve 42 to reduce the induced steam flow rate, link the cooling water temperature control valve of the water-water heat exchanger 20 to increase the cooling water flow rate, control the start and stop of the standby water pump and switch to the dual pump operation mode, and at the same time issue a thermal energy overload alarm signal.

[0089] The opening of steam control valve 42 is reduced using proportional-integral control logic, with the rate of change of the ejected steam flow rate as the feedback parameter to ensure dynamic stability of flow regulation. The cooling water temperature control valve is regulated based on a dynamic temperature-flow matching model. For example, when the temperature rise rate at condensate outlet 1 exceeds 2°C / s, the cooling water flow rate is linearly increased to 80% of the maximum design flow rate. The activation of the backup water pump is linked to the rate of drop in the tank liquid level. If the rate of drop reaches 0.5 m / h, dual-pump operation is triggered. Alarm signals are transmitted to the central monitoring system via the industrial bus protocol, activating the audible and visual alarms.

[0090] Specifically, when the system detects that the ratio of the heat enthalpy load to the heat carrying capacity exceeds 1 and lasts for 10 seconds, the steam regulating valve 42 decreases at a rate of 0.5% per second, and at the same time, the opening of the cooling water temperature control valve is increased to 60% of the preset maximum value. If the liquid level in the tank drops below the preset safety threshold within 30 seconds, the standby water pump is immediately started and forms a parallel transmission with the original running water pump. During this linkage control process, the steam flow rate change rate is monitored in real time. When the rate exceeds 3m 3 / h·s, the steam regulating valve 42 has a higher priority than other operations. The cooling water flow rate is dynamically adjusted according to the temperature change of the condensate outlet 1. For example, for every 1°C increase in temperature, the cooling water flow rate increases by 5m 3 / h. Dual-pump operation balances outlet pressure fluctuations, stabilizing the condensate flow rate within ±2% of the set value. Alarm signals include the overload level, current heat load data, and recommended operating instructions, facilitating rapid operator intervention.

[0091] As a preferred embodiment, the solution of this application is specifically implemented as follows:

[0092] When the PLC control cabinet 40 determines that a thermal overload condition exists, it first controls the steam control valve 42 to decrease its opening. Specifically, the PLC control cabinet 40 sends a control signal to the steam control valve 42 to gradually decrease its opening from its current value, for example, at a rate of 1% per second, until the ejected steam flow rate falls below a set threshold.

[0093] At the same time, the PLC control cabinet 40 controls the cooling water temperature control valve of the water-to-water heat exchanger 20 to increase the cooling water flow rate. Furthermore, the PLC control cabinet 40 adjusts the temperature control valve opening in real time based on the condensate outlet 1 temperature. For example, when the outlet temperature exceeds 85°C, the cooling water flow rate is increased by 5% per minute until the outlet temperature drops below 80°C.

[0094] Furthermore, the PLC control cabinet 40 controls the start and stop of the backup water pump, switching to dual-pump operation. Specifically, the PLC control cabinet 40 sends a start signal to the backup water pump, causing it to operate simultaneously with the main water pump to increase condensate delivery capacity. For example, the backup water pump starts within 10 seconds and adjusts the operating frequency of both water pumps to the same value.

[0095] Finally, the PLC control cabinet 40 issues a thermal overload warning signal, thereby alerting the operator through the sound and light alarm device, indicating that the system is in a thermal overload state and requires manual intervention or further adjustment.

[0096] Through the above technical solution, this application can quickly respond and take multiple measures when it is determined that a thermal overload state exists. By reducing the steam injection volume, increasing the cooling water flow rate, and starting the backup water pump, the system thermal overload condition is effectively alleviated. At the same time, an alarm signal is issued to remind the operator to further ensure the safe operation of the system. This multi-dimensional, coordinated control method improves the operating stability and energy utilization efficiency of the condensate recovery and treatment unit, and effectively prevents equipment damage and energy waste caused by thermal overload.

[0097] In some of the above-mentioned solutions of this application, the control cabinet identifies the thermal energy overload state by real-time monitoring of steam injection volume and condensate temperature data, but the system still has a response lag problem when the flow suddenly increases, and cannot predict potential overload risks in advance.

[0098] This application further proposes that the control cabinet is equipped with a thermal energy overload prediction model based on historical operating data. The thermal energy overload prediction model is based on a vector regression algorithm, and is learned based on the steam injection volume, condensate temperature and outlet pressure data in multiple historical cycles, and issues an impending overload warning when a new round of flow increases.

[0099] The thermal overload prediction model utilizes a time series analysis framework to construct a multidimensional input vector from steam injection volume, condensate outlet temperature, and pressure data at an hourly granularity. A vector regression algorithm transforms the nonlinear relationships in historical data into a high-dimensional linear space through kernel function mapping, establishing a correlation model between injection flow rate, temperature, and pressure. A sliding window mechanism is employed during model training, retaining the last 30 days of operating data as a training set for each update to ensure that the prediction results match the current operating conditions. When the steam injection flow rate increases by more than 15% month-over-month, the model automatically triggers a forecast calculation, outputting the system thermal load trend for the next five minutes.

[0100] Specifically, the control cabinet collects data from the steam flow meter 41, temperature transmitter 25, and pressure transmitter every 10 seconds to form a real-time data stream. The historical database stores the average steam injection volume, the condensate outlet 1 temperature peak, and the pressure fluctuation range every 5 minutes over the past 30 days. The vector regression model calculates the similarity between historical data and the current data stream through the radial basis kernel function to generate a heat load change rate prediction curve. If the slope of the prediction curve exceeds the preset threshold, the control cabinet will issue an early warning signal 120 seconds before the actual occurrence of thermal overload. After the early warning is triggered, the control cabinet starts the steam control valve 42 opening pre-adjustment program in advance and increases the opening of the water-water heat exchanger 20 temperature control valve to the preparatory state, so that the cooling water flow enters the incremental mode before the overload occurs. This prediction mechanism enables the system to predict the change of thermodynamic state at the initial stage of the flow surge, avoiding thermal shock of the heat exchanger caused by adjustment lag.

[0101] As a preferred embodiment, the solution of this application is specifically implemented as follows:

[0102] The PLC control cabinet 40 is equipped with a thermal overload prediction model based on historical operating data. This prediction model, using a vector regression algorithm, learns from historical data on steam injection volume, condensate temperature, and outlet pressure over multiple cycles. It issues an impending overload warning when a new round of flow increases.

[0103] Specifically, the PLC control cabinet 40 first collects data on steam injection volume, condensate temperature, and outlet pressure every 10 minutes over the past 24 hours. This data is used as a training set and input into a vector regression model. The model iteratively optimizes weight coefficients to establish a relationship between these three parameters and the thermal energy load.

[0104] In actual operation, the PLC control cabinet 40 acquires the latest data on steam injection volume, condensate temperature, and outlet pressure every minute. This real-time data is fed into a trained model to predict the thermal load trend over the next 30 minutes. If the forecast indicates that the thermal load will exceed 90% of the system's rated capacity within 15 minutes, the control cabinet issues an early warning signal indicating an impending overload.

[0105] Early warning signals include a yellow warning icon displayed on the operator interface and a text message alert sent to management. This gives operators enough time to take preventive measures, such as reducing steam injection or increasing cooling water flow, to prevent the system from actually overloading.

[0106] Through the above technical solution, this application achieves early prediction and early warning of the condensate recovery system's thermal energy load. This method, based on historical data and machine learning, is more flexible and accurate than traditional fixed threshold alarms. It can adapt to dynamic changes in the system, identify potential overload risks in advance, and provide operators with ample response time. As a result, the system's operational stability is improved, avoiding equipment damage or energy waste caused by sudden overloads, while also reducing unnecessary downtime and improving overall energy efficiency.

[0107] In some of the aforementioned solutions of this application, when the system is in a thermal overload state, intervention is implemented by adjusting the steam regulating valve 42 and the temperature control valve of the water-to-water heat exchanger 20. However, during dynamic regulation, if the opening is adjusted only based on the current flow rate or temperature parameters, the hysteresis of the parameter changes may cause oscillation or overshoot in the regulation process, thereby affecting the stability of the system pressure and thermal balance.

[0108] The present application further proposes that when it is determined that there is a thermal energy overload or an imminent overload, the opening of the steam regulating valve 42 is adjusted through proportional-integral control logic, and the steam flow rate is adjusted using the change rate of the induced steam flow rate as a feedback parameter.

[0109] The proportional-integral control logic combines proportional and integral terms. The proportional term is used to quickly respond to deviations between the injected steam flow rate and the set value, while the integral term is used to eliminate steady-state errors. The injected steam flow rate change rate is obtained by collecting data from the flow meter 44 in real time and calculating the change per unit time. This is then input into the control logic as a feedback parameter. The opening adjustment of the steam control valve 42 is determined by the proportional-integral calculation result and the weighted value of the flow rate change rate.

[0110] Specifically, when the PLC control cabinet 40 determines that there is a thermal overload, it first obtains the real-time data of the steam ejector flowmeter 44, and calculates the deviation between the current flow and the target flow and the flow change rate. The proportional term generates a preliminary adjustment amount based on the deviation value, and the integral term accumulates historical deviations to correct long-term errors. At the same time, the flow change rate is used as a dynamic compensation parameter. If the flow rises rapidly, the closing speed of the regulating valve is increased, and if the flow tends to be flat, the adjustment amplitude is reduced. The control logic superimposes the results of the three calculations and outputs them to the regulating valve actuator, so that the change in valve opening not only responds to the current deviation, but also can predict the adjustment direction according to the flow change trend. For example, when the ejected steam flow is 0.5m per second 3 When the rate of flow increases, the control algorithm will automatically increase the proportional coefficient weight so that the regulating valve will reduce the opening from 60% to 45% within 10 seconds. 3 When the pressure is adjusted, the integral term dominates the regulation process, gradually stabilizing the opening near the target value. This control method effectively avoids the pressure fluctuations caused by traditional on-off regulation and ensures a smooth transition of the system under thermal overload conditions.

[0111] As a preferred embodiment, the solution of the present application is specifically implemented as follows: During the operation of the condensate recovery and treatment unit, when the PLC control cabinet 40 determines that there is a thermal energy overload through the data of the flow meter 44 at the steam ejector inlet and the condensate outlet 1, or the prediction model issues an impending overload warning, the proportional-integral control module is activated. The opening adjustment instruction of the steam control valve 42 is generated by the PID algorithm, and its input parameters include the deviation between the real-time steam flow and the target flow, and the real-time feedback value of the rate of change of the ejected steam flow. For example, when the steam flow rate changes by more than 0.5m 3 / s 2 When the flow rate exceeds the preset safety threshold, the accumulated error of the integral term is reset to zero, preventing overshoot in the control system.

[0112] Through the above-mentioned technical solution, this application achieves refined dynamic control of steam injection flow. By introducing the flow rate change rate as a feedback parameter, it effectively suppresses drastic fluctuations in steam flow caused by sudden changes in external operating conditions, avoiding thermal stress concentration in the heat exchanger caused by valve response lag or overshoot. Furthermore, the synergistic effect of proportional-integral control logic and real-time flow data ensures a smooth transition of the system regulation process under thermal overload conditions, preventing equipment damage caused by sudden pressure increases in the condensate tank 36 or frequent starts and stops of the water pump.

[0113] In some of the above-mentioned schemes of the present application, when the opening of the steam regulating valve 42 is adjusted through the proportional-integral control logic and the steam flow is adjusted with the change rate of the induced steam flow as the feedback parameter, relying solely on the feedback of the change rate of the steam flow may cause the cooling water flow regulation to lag behind the actual change of the condensate outlet 1 temperature, and fail to match the temperature fluctuation in time, thereby affecting the effect of alleviating the thermal energy overload state.

[0114] The present application further proposes a temperature-flow dynamic matching method, so that the cooling water flow rate increases as the temperature of the condensate outlet 1 increases.

[0115] Among them, the temperature sensor collects the temperature data of the condensate outlet 1 in real time and transmits it to the PLC control cabinet 40. The PLC control cabinet 40 has a built-in mapping relationship table between temperature and cooling water flow, which defines the cooling water flow regulation gradient corresponding to different temperature ranges. The opening of the temperature control valve 24 is adjusted linearly or nonlinearly according to the flow demand corresponding to the current temperature. For example, when the temperature exceeds the set threshold, every increase of 2°C triggers a 5% increase in cooling water flow. The dynamic matching algorithm ensures a smooth transition of the adjustment process by calculating the correlation between the temperature change rate and the flow adjustment amount in real time, avoiding frequent opening and closing of the valve. The control butterfly valve 21 at the cooling water inlet forms a series structure with the temperature control valve 24. The basic opening is preset by controlling the butterfly valve 21, and the temperature control valve 24 performs fine adjustment within this range.

[0116] Specifically, when the temperature of the condensate outlet 1 rises, the PLC control cabinet 40 generates a control signal according to the preset temperature-flow curve, driving the temperature control valve 24 to increase the opening. The increase in the cooling water flow rate directly enhances the heat dissipation efficiency of the water-water heat exchanger 20, causing the condensate temperature to drop. This regulation process complements the flow control of the steam regulating valve 42. The feedback of the steam flow change rate focuses on suppressing short-term fluctuations, while the temperature-flow dynamic matching focuses on maintaining medium- and long-term thermal balance. For example, in the early stage of thermal energy overload, the steam regulating valve 42 gives priority to quickly reducing the injection flow, while the temperature rise triggers a step-by-step increase in the cooling water flow. The two work together to reduce the system heat load. The temperature sensor data is refreshed in a cycle of 0.5 seconds to ensure the real-time nature of the dynamic matching and avoid adjustment errors caused by data delays.

[0117] As a preferred embodiment, the solution of the present application is specifically implemented as follows: a temperature transmitter 25 is installed at the outlet of the condensate tank 36 to monitor the condensate temperature in real time, and the temperature signal is transmitted to the PLC control cabinet 40. When the temperature of the condensate outlet 1 rises to a preset first temperature range, the opening of the temperature control valve 24 is gradually increased, and the cooling water flow rate is increased in a linear proportion. When the temperature enters the second temperature range, the temperature control valve 24 switches to a nonlinear opening adjustment mode, and the cooling water flow rate increment is dynamically adjusted with the temperature rise rate. Specifically, the temperature transmitter 25 collects data every 30 seconds and transmits it to the control cabinet through a 4-20mA analog signal. The PID algorithm built into the control cabinet calculates the step amount of the control valve based on the temperature change slope, so that the cooling water flow rate and temperature change form a negative feedback closed-loop control.

[0118] Through the above technical solution, this application achieves real-time dynamic matching of cooling water flow rate and condensate outlet temperature, effectively avoiding the accumulation of thermal stress in the heat exchanger due to insufficient cooling capacity. When the heat load carried by the condensate fluctuates, the system automatically adjusts the cooling water flow rate, maintaining the stability of the internal temperature field of the heat exchanger, preventing equipment performance degradation caused by local overheating, and optimizing the utilization efficiency of cooling water resources.

[0119] In some of the aforementioned solutions of this application, upon determining a thermal overload, the PLC control cabinet 40 is required to adjust the opening of the steam regulating valve 42, control the temperature control valve 24 of the water-to-water heat exchanger 20, and switch the water pump. However, if multiple operations are executed simultaneously without prioritizing them, control delays or parameter coupling may cause a system response lag, preventing timely relief of the overload condition and potentially leading to further loss of control of the tank's pressure or temperature.

[0120] This application further proposes dynamically determining the optimal execution order based on the rate of change of each monitored parameter under the current operating state before executing steam control valve 42, water-to-water heat exchanger 20 temperature control valve 24, and water pump control operations. Specifically, if the rate of change of the injected steam flow exceeds a first threshold, steam control valve 42 is prioritized. If the rate of increase in the condensate outlet 1 temperature exceeds a second threshold, temperature control valve 24 is prioritized. If the rate of decrease in the tank liquid level exceeds a set limit, the backup water pump is prioritized, switching to dual-pump mode.

[0121] The first threshold is set to a change exceeding 5% of the rated flow rate per second based on historical data on the inlet flow rate of the steam ejector 3, and the second threshold is set to a rise exceeding 3°C per minute based on the temperature resistance limit of the heat exchanger material. The set limit for the rate of drop of the liquid level in the tank is calculated based on the maximum output flow of the water pump and the volume of the condensate tank 36. For example, the liquid level drops by more than 10% of the total height per minute. By collecting the rate of change of steam flow, condensate temperature, and liquid level in real time, the PLC control cabinet 40 compares the rate of change of these three parameters with preset thresholds to determine the most urgent control needs. When the steam flow rate suddenly changes, the steam valve is adjusted first to quickly reduce the heat enthalpy input. When the temperature rises rapidly, the cooling water flow is increased first to prevent overheating of the heat exchanger. When the liquid level drops suddenly, the backup water pump is activated first to prevent interruption of the condensate supply.

[0122] Specifically, when the PLC control cabinet 40 detects that the rate of change of the injected steam flow exceeds a first threshold, it determines that steam input fluctuations are the primary concern and immediately adjusts the opening of the steam control valve 42 to stabilize the flow. For example, if the steam flow suddenly increases, causing the rate of change to reach 6% / s, the steam valve opening is prioritized by linearly reducing it from 60% to 40%, restoring the injected steam flow to the rated range within 10 seconds. If the condensate outlet 1 temperature simultaneously rises at a rate of 4°C / min, because the temperature change rate does not exceed the second threshold, temperature control valve adjustment is delayed until the steam flow stabilizes. When the liquid level drops at a rate of 12% / min, the PLC control cabinet 40 prioritizes activating the backup water pump, increasing the total flow of the two pumps to 1.8 times that of the single pump, ensuring that the condensate output matches the rate of decline in the tank liquid level. This dynamic priority mechanism, through quantitative analysis of real-time parameter change rates, enables the control system to accurately identify the dominant factor in an overload state, avoiding regulatory conflicts caused by cross-interference among multiple parameters and restoring system thermal balance in the shortest possible time.

[0123] As a preferred embodiment, the solution of the present application is specifically implemented as follows: in the state of thermal energy overload, the control cabinet dynamically selects the execution order according to the rate of change of the current operating parameters. When the rate of change of the induced steam flow exceeds 2.5 cubic meters per second, the opening of the steam regulating valve 42 is adjusted first to suppress the sudden change of the flow. If the temperature rise rate of the condensate outlet 1 exceeds 8 degrees Celsius per minute, the opening of the temperature control valve 24 of the water-water heat exchanger 20 is increased first to enhance cooling. When it is detected that the rate of decrease of the liquid level in the tank exceeds 15% of the rated capacity per hour, the backup water pump is immediately started and switched to the dual pump operation mode. The above judgment logic uses a built-in algorithm to analyze the data change gradient of the pressure transmitter, temperature transmitter 25 and liquid level gauge in real time, and generates a control instruction sequence according to the preset priority threshold.

[0124] Through the above technical solution, the present application effectively solves the problem of system instability that may be caused by a single control strategy under a thermal overload state. By dynamically analyzing the rate of change of each key parameter, it is possible to accurately identify the most urgent system risk point and give priority to executing the corresponding control action. For example, when the steam flow fluctuates violently, the steam valve is adjusted first to avoid damage to the equipment due to sudden pressure changes. When the temperature rises rapidly, cooling is strengthened first to prevent the thermal stress of the heat exchanger from exceeding the limit. When the liquid level drops sharply, the backup pump is started in time to ensure the continuous operation of the system. This intelligent decision-making mechanism based on real-time data characteristics improves the system's coordinated control capabilities in response to complex working conditions and avoids the response lag or operation conflicts that may occur in the traditional fixed control sequence.

[0125] The above-mentioned embodiment overcomes the high energy consumption, uncontrollable leakage, and unbalanced heat load issues inherent in conventional technologies by constructing an integrated condensate recovery and treatment unit with multi-stage condensate adaptability, a steam leak warning mechanism, and dynamic heat energy regulation. Independent high-, medium-, and low-pressure condensate inlets, along with comprehensive pressure, temperature, and level monitoring components, are provided on the condensate tank, enabling unified condensate recovery from multiple sources and dynamic operating condition identification. An internally integrated water-to-water heat exchanger with baffles and a flow guide and booster device improves heat exchange efficiency and flow stability. A controllable steam heat recovery channel is established by providing a steam ejector pipe and its associated ejector, flowmeter, and regulating valve assembly. A wireless steam leak detection device is deployed at the steam trap end, combined with the signal reception and warning capabilities of the PLC control cabinet, enabling real-time identification and response to steam leaks. Based on a dynamic comparison of steam ejection volume with the outgoing condensate flow rate and temperature, the thermal load status is determined in real time, and the steam valve, temperature control valve, and water pump operating strategies are automatically coordinated and adjusted to ensure system thermal balance and efficient operation. The safety, stability and energy efficiency of the condensate recovery system under complex working conditions have been improved.

[0126] Those skilled in the art will appreciate that the embodiments of the present application may be provided as methods, systems, or computer program products. Therefore, the present application may take the form of a complete hardware embodiment, a complete software embodiment, or a combination of software and hardware embodiments. Furthermore, the present application may take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to magnetic disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0127] The present application is described with reference to the flowcharts and / or block diagrams of the methods, devices (systems) and computer program products according to the embodiments of the present application. It should be understood that each process and / or box in the flowchart and / or block diagram, as well as the combination of the processes and / or boxes in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor or other programmable data processing device to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 a process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0128] These computer program instructions may also be stored in a computer readable memory that can direct a computer or other programmable data processing device to work in a specific manner, so that the instructions stored in the computer readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 a process or multiple processes and / or boxes Figure 1 The function specified in one or more boxes.

[0129] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operational steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing the instructions executed on the computer or other programmable device for implementing the process. Figure 1 a process or multiple processes and / or boxes Figure 1 A step that specifies a function in one or more boxes.

[0130] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, ordinary technicians in the field should understand that the specific implementation methods of the present invention can still be modified or replaced by equivalents. Any modification or equivalent replacement that does not depart from the spirit and scope of the present invention should be covered by the scope of protection of the claims of the present invention.

Claims

1. A condensate recovery unit with leakage warning and digitalization, characterized in that: include: The condensate tank is provided with a high-pressure condensate inlet, a medium-pressure condensate inlet and a low-pressure condensate inlet. The condensate tank is provided with a pressure gauge assembly, a pressure transmitter assembly, a temperature transmitter and a remote liquid level gauge. The pressure gauge assembly, the pressure transmitter assembly, the temperature transmitter and the remote liquid level gauge are respectively used to monitor the pressure, temperature and liquid level information inside the condensate tank. A water-water heat exchanger with a baffle is provided inside the condensate tank. The outlet of the condensate tank is connected to a built-in diversion and pressurizing device. A steam ejector is provided on the top of the condensate tank. A steam flow meter, a regulating valve and a check valve are provided on the steam ejector, and the check valve is connected to the ejected port of the steam ejector; The cooling water outlet of the water-water heat exchanger is connected to a temperature control valve, and the cooling water inlet is provided with a control butterfly valve; A plurality of steam traps, each of which is provided with a steam ultrasonic leak detection device, wherein the steam ultrasonic leak detection device transmits a signal wirelessly; At least two water pumps are provided, the water pumps are connected to the outlet of the built-in diversion and boosting device and lead to the steam ejector through a pipeline; the outlet of the steam ejector is connected to the condensate output pipe and is provided with a flow meter; The PLC control cabinet is configured to receive data from sensors, including steam traps, pressure transmitters, temperature transmitters, liquid level gauges, and flow meters. The PLC control cabinet is also configured to identify steam leaks and issue early warnings. Based on the flow data of the ejected steam and the exported condensate, it determines in real time whether the system is in a thermal overload state. It also regulates the steam regulating valve and the water-to-water heat exchanger temperature control valve in a coordinated manner, and controls the start and stop of the water pump.

2. The condensate recovery and treatment unit with leakage warning and digitization according to claim 1 is characterized in that: Also includes: The steam ejector is provided with a stop valve, and the stop valve is used to cut off the ejection channel.

3. The condensate recovery and treatment unit with leakage warning and digitization according to claim 1 is characterized in that: There are two flow meters, which are installed at the inlet and condensate outlet of the steam ejector respectively, and are used to collect ejection and output flow data in real time.

4. The condensate recovery and treatment unit with leakage warning and digitization according to claim 1 is characterized in that: When the PLC control cabinet identifies a steam leak and issues an early warning, it includes: The PLC control cabinet receives a wireless signal sent by a steam trap equipped with a steam ultrasonic leak detection device, wherein the wireless signal includes the current temperature, pressure, ultrasonic frequency amplitude and frequency energy spectrum of the steam trap; Performing spectrum analysis on the wireless signal to extract high-frequency noise characteristic factors, transient peak changes, and frequency domain energy parameters compared with standard thresholds; Based on the leakage pattern database, it identifies whether there is a leakage state, and issues a leakage warning when the identification result meets the leakage threshold condition.

5. The condensate recovery and treatment unit with leakage warning and digitization according to claim 1 is characterized in that: The PLC control cabinet determines whether the system is in a heat overload state in real time based on the flow data of the injected steam and the outgoing condensate, including: The PLC control cabinet obtains data from the steam flow meter on the steam ejector pipe and a built-in steam enthalpy database, and obtains the enthalpy load of the ejected steam according to the steam pressure and temperature; Obtain data from the condensate output flow meter and temperature transmitter, and combine this with the specific heat capacity of water to obtain the heat carrying capacity of the outlet condensate; The ratio data of the thermal enthalpy load and the heat carrying capacity is obtained. When the ratio data exceeds 1 and the ratio data is greater than the upper limit of the heat exchanger load, the PLC control cabinet determines that a thermal energy overload state exists.

6. The condensate recovery and treatment unit with leakage warning and digitization according to claim 5 is characterized in that: When the PLC control cabinet determines that a thermal energy overload state exists, the process includes: The PLC control cabinet controls the steam regulating valve to reduce its opening, thereby reducing the ejected steam flow rate; links the water-water heat exchanger cooling water temperature control valve to increase the cooling water flow rate; controls the start and stop of the standby water pump, switching to a dual-pump operation mode; and issues a thermal energy overload alarm signal.

7. The condensate recovery and treatment unit with leakage warning and digitization according to claim 6 is characterized in that: The PLC control cabinet is also equipped with a thermal energy overload prediction model based on historical operating data. The thermal energy overload prediction model is based on a vector regression algorithm and learns from the steam injection volume, condensate temperature and outlet pressure data in multiple historical cycles, and issues an impending overload warning when a new round of flow increases.

8. The condensate recovery and treatment unit with leakage warning and digitization according to claim 6 is characterized in that: When the PLC control cabinet is linked to regulate the steam regulating valve and the water-water heat exchanger temperature control valve, it includes: When the PLC control cabinet determines that there is a thermal overload or is about to be overloaded, it adjusts the opening of the steam regulating valve through proportional-integral control logic, and adjusts the steam flow rate using the change speed of the induced steam flow rate as a feedback parameter.

9. The condensate recovery and treatment unit with leakage warning and digitization according to claim 8 is characterized in that: When the PLC control cabinet jointly adjusts the temperature control valve of the water-water heat exchanger, it includes: based on temperature-flow dynamic matching, the cooling water flow rate increases as the condensate outlet temperature increases.

10. The condensate recovery and treatment unit with leakage warning and digitization according to claim 9 is characterized in that: When the PLC control cabinet determines that a thermal energy overload state exists, the method further includes: Before executing the steam regulating valve, water-water heat exchanger temperature control valve and water pump control operations, the PLC control cabinet dynamically determines the optimal execution strategy order based on the change rate of each monitoring parameter under the current operating state, where: If the rate of change of the injected steam flow rate is higher than the first threshold, the steam regulating valve control is performed first; If the rising rate of the condensate outlet temperature is higher than the second threshold, the temperature control valve is adjusted first; If the rate of drop of the liquid level in the tank is higher than the set limit, the standby water pump will be started first and switched to dual pump mode.

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