Shaft heater steam trap monitoring system and control method thereof

Abstract

The invention discloses a shaft heater steam trap monitoring system and a control method thereof, and aims to solve the problems that the judgment basis of the operation state condition of a shaft heater steam trap is single, misjudgment exists, and real-time monitoring and early warning cannot be achieved. The system comprises a data acquisition module, a data processing module, a control module and a display execution module, the acquisition module is used for acquiring operation data; the data processing module is used for judging the operation condition of the shaft heater steam trap by utilizing a preset data analysis model according to the operation data to generate a judgment result; the control module is used for generating a corresponding control instruction based on a preset grading response library according to the judgment result and the operation data; and the display execution module is used for executing a corresponding display action according to the control instruction. Through data acquisition, processing, control and display, all the data are quantitatively acquired, the model is objectively judged, manual subjective intervention is not needed, missed judgment during manual inspection is avoided, and the reliability of working condition judgment is improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of auxiliary equipment monitoring of thermal power plants, and particularly discloses a shaft drain trap monitoring system and a control method thereof. BACKGROUND

[0002] The shaft seal heater is a device for recovering the exhaust steam of the shaft seal of a steam turbine and heating the condensate using the heat thereof. The shaft seal heater can reduce heat loss and improve the heat exchange efficiency of the unit. The main components of the system include a shaft seal heater body, a shaft seal heater fan, a shaft drain trap, and supporting pipes, valves, meters, etc.

[0003] The shaft drain trap usually adopts a free-floating ball drain trap, which has a simple structure and no vulnerable parts. The shaft drain trap has a stainless steel hollow ball inside, is provided with a cold air passage, and is provided with a set of filter screens for separating impurities in the upstream steam-water mixture. After the shaft seal steam system is put into use, the air in the system pipeline is initially discharged into the condenser through the cold air discharge device; after entering the drain stage, a large amount of condensate in the shaft seal steam system enters the drain trap, the liquid level rises to drive the ball to float, the nozzle passage is opened to discharge the condensate; finally, when steam is generated and enters the drain trap, the drain trap is rapidly heated, the temperature-sensitive liquid in the cold air discharge device expands and automatically closes the cold air discharge valve, as the drain amount decreases, the liquid level of the drain trap gradually decreases, and finally the ball falls to close the nozzle passage and lock the steam in the system. When the system is continuously running, the ball will dynamically adjust the valve opening to complete the drainage as the steam-water mixture enters.

[0004] In actual production, when the unit is started in a cold state, a large amount of drain will be generated in the shaft seal steam system, and a large amount of metal impurities and sediments will be generated in the shaft seal steam pipeline due to long-term steam scouring. The two superimposed factors make the filter screen of the shaft drain trap easily clogged. The shaft seal steam drain backflow causes the shaft seal fan to throw water; the poor exhaust of the shaft seal causes a large amount of steam to escape from the shaft ends of the steam turbine, which burns the transmitters; the shaft seal steam enters the bearing oil chamber, causing the lubricating oil to emulsify; the water in the main engine oil tank causes the liquid level to abnormally rise, and other accidents.

[0005] The existing shaft drain trap is usually assisted in judging the running condition of the shaft drain trap by using the temperature difference before and after the shaft drain trap as a reference, which often needs manual contact and judgment by the operator, has high requirements for the experience of the operator, has single judgment basis, and cannot realize real-time monitoring and early warning, which has the problems of large safety hidden danger, lagging response, etc. SUMMARY

[0006] (I) Invention purpose

[0007] The purpose of the present application is to provide a shaft drain trap monitoring system and a control method thereof, which aims to solve the problems of single judgment basis for the running condition of the shaft drain trap, misjudgment, and inability to realize real-time monitoring and early warning.

[0008] (II) Technical Solution

[0009] To solve the above problems, the first aspect of the present application provides a shaft trap monitoring system, comprising a data acquisition module, a data processing module, a control module and a display execution module, the acquisition module, data processing module, control module and display execution module are connected in turn.

[0010] The acquisition module is used to acquire the running data of the shaft trap, and the running data includes the inlet and outlet fluid temperature, inlet and outlet flow data and shaft fan inlet pressure value of the shaft trap.

[0011] The data processing module is used to judge the running condition of the shaft trap according to the running data and utilize the preset data analysis model to generate a judgment result.

[0012] The control module is used to generate a corresponding control instruction based on the judgment result and running data and the preset hierarchical response library.

[0013] The display execution module is used to execute a corresponding display action according to the control instruction.

[0014] Preferably, the acquisition module comprises a temperature detection unit, a flow detection unit and a pressure detection unit.

[0015] The temperature detection unit is arranged at the inlet and outlet of the shaft trap respectively, and is used to acquire the inlet temperature and outlet temperature.

[0016] The flow detection unit is arranged at the inlet and outlet of the shaft trap respectively, and is used to acquire the inlet flow and outlet flow.

[0017] The pressure detection unit is arranged at the inlet of the shaft fan, and is used to acquire the inlet pressure.

[0018] Preferably, the data processing module comprises a data processing unit and a data analysis unit.

[0019] The data processing unit is used to amplify and analog-digital convert the running data.

[0020] The data analysis unit is used to compare and analyze the processed data with the preset data analysis model.

[0021] Preferably, the data analysis model is a multi-parameter joint analysis model based on temperature difference value, pressure value, pressure fluctuation value and flow value, and the data model comprises normal condition parameter range, blockage condition parameter range and fault condition parameter range.

[0022] Preferably, the normal condition parameter range comprises a temperature difference less than a preset temperature difference threshold, a pressure value between a first pressure threshold and a second pressure threshold, a pressure fluctuation value less than a fluctuation threshold, and a flow value between a first flow threshold and a second flow threshold.

[0023] The blocked condition parameter range comprises at least one of a temperature difference greater than or equal to a temperature difference threshold, a pressure value exceeding between the first pressure threshold and the second pressure threshold, a pressure fluctuation value greater than or equal to a fluctuation threshold, and a flow value exceeding between the first flow threshold and the second flow threshold.

[0024] The fault condition parameter range comprises any one of the temperature detection unit, the flow detection unit and the pressure detection unit.

[0025] Preferably, the hierarchical response library comprises:

[0026] The first response level comprises generating a normal operation control instruction when the data deviates from the normal condition parameter range;

[0027] The second response level comprises generating a warning level control instruction when the data meets the blocked condition parameter range;

[0028] The third response level comprises generating an emergency level control instruction when the data meets the fault condition parameter range.

[0029] Preferably, the display execution module comprises an indicator light group, and the indicator light group is used to display different color light states according to the control instruction.

[0030] Preferably, the system further comprises a communication module, and the communication module is used for data communication with the host computer, uploading operation data, alarm information and receiving remote control instructions.

[0031] Preferably, the system further comprises a data storage module, and the data storage module is used to store historical operation data, fault records and operation logs.

[0032] Another aspect of the present application provides a control method of a shaft plus trap monitoring system, comprising:

[0033] Collecting operation data of the shaft plus trap, the operation data comprising inlet and outlet fluid temperature, inlet and outlet flow data and shaft plus fan inlet pressure value of the shaft plus trap;

[0034] According to the operation data, using a preset data analysis model to judge the operation condition of the shaft plus trap, and generating a judgment result;

[0035] According to the judgment result and the operation data, generating a corresponding control instruction based on a preset hierarchical response library;

[0036] The corresponding display action is executed according to the control command.

[0037] (III) Beneficial Effects

[0038] The above-described technical solution of the present invention has the following beneficial technical effects:

[0039] 1. Through data acquisition, processing, control, and display, all data is quantitatively collected and objectively judged by the model, eliminating the need for subjective human intervention. When the shaft-mounted steam trap filter begins to slightly clog, the acquisition module can detect subtle changes such as an increase in the difference between the inlet and outlet flow rates and an increase in the temperature difference. The data processing module quickly identifies these changes through the model, avoiding missed judgments during manual inspections and improving the reliability of operational condition judgments.

[0040] 2. This system collects three types of data: temperature, flow rate, and pressure. The data processing module performs comprehensive analysis using a multi-parameter joint model. This multi-dimensional collaborative analysis avoids the limitations of single-parameter monitoring, ensuring more comprehensive and accurate judgment of operating conditions and effectively preventing false alarms and missed alarms.

[0041] 3. The control module of this system is based on a graded response library, generating differentiated instructions according to the severity of the operating condition. This graded response avoids production interruptions caused by over-processing and prevents minor anomalies from escalating into serious failures, achieving a balance between safety and continuity. Attached Figure Description

[0042] Figure 1 This is a schematic diagram of the overall structure of a shaft-mounted condensate drain monitoring system provided by the present invention;

[0043] Figure 2 This is a top view of the shaft-mounted drainer according to one embodiment of the present invention;

[0044] Figure 3 This is a flowchart of a control method for a shaft-mounted condensate drain monitoring system provided by the present invention.

[0045] Figure label:

[0046] 1. Shaft-mounted steam trap; 1a. Inlet flange; 1b. Outlet flange; 11. Upper cover of shaft-mounted steam trap;

[0047] 2. First thermocouple; 3. Second thermocouple; 4. LED indicator. Detailed Implementation

[0048] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments and the accompanying drawings. It should be understood that these descriptions are merely exemplary and not intended to limit the scope of the invention. Furthermore, descriptions of well-known structures and techniques are omitted in the following description to avoid unnecessarily obscuring the concept of the invention.

[0049] The accompanying drawings illustrate a layer structure according to an embodiment of the present invention. These drawings are not to scale, and some details have been enlarged for clarity, and some details may have been omitted. The shapes of the various regions and layers shown in the drawings, as well as their relative sizes and positional relationships, are merely exemplary and may deviate from reality due to manufacturing tolerances or technical limitations. Furthermore, those skilled in the art can design regions / layers with different shapes, sizes, and relative positions as needed.

[0050] Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0051] Combination Figure 1 The first aspect of the present invention provides a monitoring system for a shaft-fed steam trap 1, comprising a data acquisition module, a data processing module, a control module, and a display execution module, which are connected sequentially. The acquisition module is used to acquire operating data of the shaft-fed steam trap 1, including inlet and outlet fluid temperatures, inlet and outlet flow rates, and inlet pressure values ​​of the shaft-fed fan. The data processing module is used to judge the operating condition of the shaft-fed steam trap 1 based on the operating data using a preset data analysis model and generate a judgment result. The control module is used to generate corresponding control commands based on the judgment result and the operating data, using a preset hierarchical response library. The display execution module is used to execute corresponding display actions according to the control commands.

[0052] Specifically, the data acquisition module obtains key operational data from the shaft-mounted steam trap 1 and related systems, overcoming the limitations of traditional manual temperature measurement which cannot quantify and collect multi-dimensional data. Through three types of detection devices—temperature, flow rate, and pressure—physical quantities such as the inlet and outlet fluid temperature and flow rate of the shaft-mounted steam trap 1, and the inlet pressure of the shaft-mounted fan are converted into transmittable electrical signals, such as the electromotive force of thermocouples and the current signal of transmitters, providing raw data support for subsequent analysis. The data processing module receives the raw data from the acquisition module, calls a preset multi-parameter joint analysis model, integrates the correlation logic of temperature difference, pressure, and flow rate, and determines whether the shaft-mounted steam trap 1 is in a normal, blocked, or faulty state through data comparison, generating a judgment result. Based on the judgment result from the data processing module and combined with real-time operational data, the control module matches the corresponding response strategy from a preset hierarchical response library, generating differentiated control commands, such as normal prompts, blockage warnings, or emergency fault commands. The display execution module receives the commands from the control module and converts the judgment result into intuitive display actions, such as light or text prompts, allowing maintenance personnel to quickly grasp the equipment status.

[0053] With this setup, data acquisition, processing, control, and display are all quantified and objectively judged by the model, eliminating the need for subjective human intervention. When the filter screen of the shaft-mounted steam trap begins to slightly clog, the acquisition module can detect subtle changes such as an increase in the difference between the inlet and outlet flow rates and a rise in the temperature difference. The data processing module quickly identifies these changes using the model, avoiding missed detections during manual inspections and improving the reliability of operational condition assessments. This system collects three types of data: temperature, flow rate, and pressure. The data processing module performs comprehensive analysis using a multi-parameter joint model. This multi-dimensional collaborative analysis avoids the limitations of single-parameter monitoring, ensuring more comprehensive and accurate operational condition assessments and effectively preventing false alarms and missed alarms. The system's control module generates differentiated commands based on the severity of the operational condition, using a tiered response library. This tiered response avoids production interruptions caused by over-processing and prevents minor anomalies from escalating into serious faults, achieving a balance between safety and continuity.

[0054] In a preferred embodiment, the data acquisition module includes a temperature detection unit, a flow detection unit, and a pressure detection unit; the temperature detection units are respectively located at the inlet and outlet of the shaft-mounted steam trap 1, and are used to acquire the inlet temperature and the outlet temperature; the flow detection units are respectively located at the inlet and outlet of the shaft-mounted steam trap 1, and are used to acquire the inlet flow rate and the outlet flow rate; the pressure detection unit is located at the inlet of the shaft-mounted fan, and is used to acquire the inlet pressure.

[0055] Specifically, the temperature detection unit accurately collects the inlet and outlet fluid temperatures of the shaft-mounted steam trap 1, providing basic data for calculating the temperature difference. The temperature difference is a key indicator for judging filter blockage; blockage hinders drainage, impedes heat exchange between the inlet and outlet, and increases the temperature difference. The flow detection unit detects the drainage volume at the inlet and outlet of the shaft-mounted steam trap 1, assisting in judging filter patency. Blockage obstructs drainage flow, resulting in a significantly lower outlet flow rate than inlet flow rate. The pressure detection unit detects the inlet pressure of the shaft-mounted fan, indirectly reflecting the operating status of the shaft-mounted steam trap 1. If the steam trap is blocked, impeded steam exhaust from the shaft seal will lead to abnormal negative pressure at the fan inlet and increased pressure fluctuations.

[0056] This setup separates the three types of data into independent detection units, with each unit collecting only one type of data. For example, the temperature detection unit focuses on the electromotive force signal, avoiding interference from the flow transmitter's current signal; the pressure detection unit collects the negative pressure signal separately, unaffected by temperature changes. This categorized acquisition method ensures the accuracy of each type of data and avoids misjudgments due to signal interference. When the system indicates an anomaly, the fault source can be quickly located through the independent detection units. For instance, when a blockage warning is displayed, if the temperature difference increases and the flow rate decreases, it can be directly determined that the filter is blocked, without needing to check other equipment one by one; if only the pressure fluctuation increases, the status of the shaft fan can be checked first, significantly narrowing the scope of fault diagnosis and greatly shortening maintenance time. It also avoids data acquisition interruptions or distortions caused by changes in operating conditions, ensuring the system's 24 / 7 monitoring capability.

[0057] In a preferred embodiment, the data processing module includes a data processing unit and a data analysis unit; the data processing unit is used to amplify and perform analog-to-digital conversion on the running data; the data analysis unit is used to compare and analyze the processed data with a preset data analysis model.

[0058] Specifically, the data processing unit processes the raw data from the acquisition module, addressing the issues of weak and inconsistent raw signals. This can be achieved by first amplifying the weak electromotive force signal (typically in the millivolt range) output by the temperature detection unit into a recognizable voltage signal (e.g., 0-5V) using an amplification circuit, such as a differential amplifier; then converting the analog signal (voltage, current) into a digital signal using an analog-to-digital converter to ensure the data processing module can recognize and calculate it; finally, filtering the data to remove transient interference, such as signal jumps caused by voltage fluctuations. The data analysis unit compares the processed digital signal with a preset model to generate an objective judgment result. It reads the digital signals output by the data processing unit, such as temperature difference, pressure, and flow rate, and calls a preset multi-parameter joint analysis model. It compares the real-time data with the normal, congested, and faulty operating condition parameter ranges in the model one by one. If the real-time data matches a certain operating condition range, a corresponding judgment result is generated and transmitted to the control module.

[0059] With this setup, the data processing unit amplifies weak signals to a identifiable range through amplification, analog-to-digital conversion, and filtering, converting them into unified digital signals while removing interference. For example, the interfered temperature electromotive force signal is amplified using a differential amplifier circuit, and then noise is removed, reducing temperature difference calculation errors and ensuring data accuracy. The data analysis unit forms a unified judgment logic through a preset multi-parameter joint analysis model. This model-based analysis ensures the consistency of the judgment logic, and the system judges operating conditions according to unified standards, avoiding misjudgments or omissions caused by differences in experience, thus improving system reliability.

[0060] In the preferred embodiment, the data analysis model is a multi-parameter joint analysis model based on temperature difference, pressure value, pressure fluctuation value and flow rate value. The data model includes the parameter range of normal operating condition, the parameter range of blocked operating condition, and the parameter range of fault operating condition.

[0061] Specifically, the data analysis model provides judgment criteria for the data processing module, ensuring the objectivity and consistency of operating condition judgments. This model integrates four types of parameters: temperature difference reflecting heat exchange efficiency, pressure value reflecting shaft seal steam exhaust smoothness, pressure fluctuation value reflecting system stability, and flow rate value reflecting condensate channel unobstructedness. This covers the key operational dimensions of the shaft seal steam trap 1, avoiding the one-sidedness of judging based on a single parameter. The four types of parameters are divided into three operating condition ranges: normal, blocked, and fault. Under normal operating conditions, all parameters are within a preset reasonable range; under blocked operating conditions, at least one parameter deviates from the reasonable range; under fault operating conditions, parameters deviate significantly or the detection unit malfunctions, such as no data output. The data analysis unit compares real-time data with the parameter ranges in the model to match the corresponding operating condition type.

[0062] In a preferred embodiment, the normal operating condition parameter range includes a temperature difference value less than a preset temperature difference threshold, a pressure value between a first pressure threshold and a second pressure threshold, a pressure fluctuation value less than a fluctuation threshold, and a flow rate value between a first flow rate threshold and a second flow rate threshold. The blockage operating condition parameter range includes at least one of the following: a temperature difference value greater than or equal to a temperature difference threshold, a pressure value exceeding the first pressure threshold and the second pressure threshold, a pressure fluctuation value greater than or equal to a fluctuation threshold, and a flow rate value exceeding the first flow rate threshold and the second flow rate threshold. The fault operating condition parameter range includes abnormal parameters or a malfunction in any one of the temperature detection unit, flow detection unit, and pressure detection unit.

[0063] Specifically, by setting specific parameter thresholds, such as temperature difference threshold, pressure threshold, and fluctuation threshold, continuous operating data is divided into discrete operating condition intervals. When all parameters are within the normal threshold, it is judged as normal; when at least one parameter exceeds the normal threshold, it is judged as blocked; when each detection unit has no data or there are obvious abnormalities in the parameters, such as temperature, air pressure, or flow exceeding the threshold and being obviously unreasonable, it is judged as a fault.

[0064] This multi-parameter joint model, by comparing four types of parameters simultaneously—temperature difference, pressure, pressure fluctuation, and flow rate—significantly reduces the probability of misjudgments caused by single-parameter anomalies, ensuring more reliable results. Operating conditions are categorized into normal, blocked, and fault conditions, with fault conditions specifically covering anomalies in detection units, such as no data from any detection unit or significant parameter deviations, such as a sudden pressure spike to 0 kPa. For example, if a pressure detection unit disconnects, resulting in no pressure data, the model can immediately identify it as a fault condition, prompting maintenance personnel to check sensors or related equipment, preventing system malfunctions due to missed faults. Clearly defined thresholds and judgment criteria ensure that the data processing module performs judgments according to a unified standard regardless of whether the unit is cold-starting, operating normally, or experiencing load changes, thus improving system stability.

[0065] In a preferred embodiment, the graded response library includes: a first response level that generates a normal operation control command when the data is within the normal operating condition parameter range; a second response level that generates a warning-level control command when the data meets the blockage operating condition parameter range; and a third response level that generates an emergency-level control command when the data meets the fault operating condition parameter range.

[0066] Specifically, a correspondence between operating conditions and response measures is established, and a three-level response mechanism is implemented. Corresponding measures are taken based on the severity of anomalies to achieve differentiated and precise operating condition responses. After receiving the judgment results from the data processing module, the control module matches the corresponding level instruction from the hierarchical response library to ensure that the response measures are adapted to the operating conditions.

[0067] Through this configuration, the tiered response library matches measures based on the severity of the operating condition. For example, when the data is within the normal range, the first response level is triggered, generating a normal operation command, allowing maintenance personnel to intuitively understand the current normal operation status. When the data indicates a blockage, the second response level is triggered, generating a warning command to prompt planned cleanup, ensuring production is not interrupted while preventing the blockage from worsening. When the data indicates a fault, the third response level is triggered, generating an emergency command to immediately shut down the system for troubleshooting, preventing the risk of equipment malfunction or misjudgment due to missing data. The tiered response library can also provide a progressive response of early warning, planned processing, and emergency intervention. The first response level ensures the system is in normal operating condition, the second response level triggers a warning at the initial stage of blockage, and the third response level intervenes immediately when a fault occurs to prevent impact on the main equipment. When a detection unit suddenly fails, the system immediately triggers the third level, shutting down for troubleshooting to avoid misjudgment of blockage due to data distortion, leading to blind cleaning of the filter and unnecessary disassembly and inspection losses, while ensuring the continuous and stable operation of the system.

[0068] In a preferred embodiment, the display execution module includes an indicator light group, which is used to display different colored light states according to control commands, including: under a normal operation control command, the indicator light group displays a green light; under a warning control command, the indicator light group displays a yellow light; and under an emergency control command, the indicator light group displays a red light.

[0069] Specifically, the indicator light group transforms abstract control commands into intuitive visual signals, allowing maintenance personnel to quickly and accurately grasp the current operating status. The indicator lights on the display execution module correspond one-to-one with the control commands: normal operation control commands illuminate the green light, indicating normal operating conditions; warning-level control commands illuminate the yellow light, indicating a blockage warning; and emergency-level control commands illuminate the red light, indicating an urgent fault. The indicator light group is installed in a prominent position on the shaft-mounted steam trap 1, such as on the upper cover 11 of the shaft-mounted steam trap, facilitating quick assessment of the operating status by maintenance personnel.

[0070] With this setup, the indicator lights directly map operating conditions by color: green indicates normal operation, yellow indicates a blockage warning, and red indicates a fault. Maintenance personnel can directly assess the operating conditions based on the indicator lights, quickly grasp the status of all equipment, and improve inspection efficiency. Simultaneously, the intuitive judgment logic avoids missed or incorrect assessments due to insufficient experience among maintenance personnel. Furthermore, the stable color display of the indicator lights prevents display failures caused by environmental factors such as dust or smoke obstruction, ensuring that maintenance personnel can always obtain operating condition information.

[0071] In a preferred embodiment, the system further includes a communication module, which is used to communicate with the host computer, upload operating data and alarm information, and receive remote control commands.

[0072] Specifically, the communication module enables remote data interaction between the system and a host computer, such as a power plant central monitoring platform, overcoming the limitations of traditional on-site monitoring and supporting remote monitoring, centralized management, and emergency intervention. The communication module uses standardized communication protocols, such as RS485 and Ethernet TCP / IP. One end connects to the system's control module, and the other end connects to the host computer. On the one hand, it uploads the system's collected operational data and alarm information to the host computer in real time; on the other hand, it receives remote control commands from the host computer, such as remotely resetting the system or adjusting model thresholds, and transmits them to the control module for execution.

[0073] With this setup, the communication module uploads data to the host computer in real time, allowing maintenance personnel to view the operating status of all shaft-mounted drain condensate coils (1) in the central monitoring room without frequent on-site inspections. If the system triggers an alarm, such as a red light fault, the host computer immediately displays a pop-up notification, allowing maintenance personnel to be informed immediately without waiting for on-site inspections. This remote monitoring method significantly reduces the frequency of on-site inspections and substantially lowers maintenance costs. Large power plants typically have multiple shaft-mounted drain condensate coils (1), and traditional methods require on-site management of each one, making overall coordination difficult. The communication module streams data from all devices to the host computer, forming a centralized monitoring interface. Maintenance personnel can view the operating status of all devices on a single interface and quickly identify abnormal devices. Simultaneously, the host computer can statistically analyze the operating data of all devices, such as monthly blockage counts or fault types, generating analysis reports for targeted screening or early maintenance, significantly improving the efficiency of multi-device management.

[0074] In a preferred embodiment, the system also includes a data storage module for storing historical operating data, fault records, and operation logs.

[0075] Specifically, the data storage module permanently stores various types of data generated during system operation, providing data support for fault tracing, maintenance optimization, and compliance checks. The data storage module uses high-capacity, high-reliability storage media, such as industrial-grade SD cards or solid-state drives, to store historical operating data, fault records (fault occurrence time, data at the time of fault, and processing results), and operation logs (control command generation time and manual intervention operations) in real time. It also supports data export, such as via a USB interface, for subsequent analysis.

[0076] Combination Figure 2In an optional configuration, holes are drilled after the inlet flange 1a and before the outlet flange 1b of the shaft-mounted steam trap 1, and K-type armored first thermocouple 2 and second thermocouple 3 are installed respectively to measure the fluid temperature before and after the shaft-mounted steam trap 1. The first thermocouple 2 and second thermocouple 3 generate an electromotive force ΔE due to the temperature difference. Subsequently, in the data processing module, the electromotive force ΔE is converted into a voltage signal through a differential amplifier circuit, and then the voltage signal is converted into a digital signal, i.e., the temperature difference ΔT, and the result is transmitted to the control module and stored in the data storage module. A pressure transmitter is installed in series after the pressure gauge at the inlet of the shaft-mounted fan. The pressure transmitter is used to monitor the negative pressure value P at the inlet of the shaft-mounted fan and the vacuum sloshing amplitude, i.e., the pressure change value ΔP, and then the data is transmitted to the control module and stored in the data storage module. Holes are drilled at the inlet and outlet positions of the shaft-mounted steam trap 1, and flow transmitters Q1 and Q2 (not shown in the figure) are installed. The flow transmitters transmit the inlet and outlet flow data of the shaft-mounted steam trap 1 to the control module and are stored in the data storage module. The data storage module is equipped with a large-capacity hard drive to store historical data under different operating conditions of the unit. Based on this data, a constructed joint analysis model can be used, and the model is written into the data processing module. The data processing module has data analysis and noise reduction capabilities. It reads temperature, pressure, and flow data in real time, uses active noise reduction to filter out occasional abnormal fluctuations in each parameter, and performs a three-dimensional comparison with the entered temperature, pressure, and flow joint analysis model. Finally, it makes a judgment on the operating condition of the shaft-mounted steam trap 1, sends the judgment result to the control module, and drives the corresponding LED indicator 4 in the display execution module to light up.

[0077] During the operation of the shaft-mounted steam trap 1, when the temperature difference before and after the shaft-mounted steam trap 1 is <3℃; the inlet pressure of the shaft-mounted fan is between -6kPa and -4.5kPa, and the fluctuation amplitude is <1kPa; and the condensate flow is normal, LED indicator 4 will light up green to indicate that the shaft-mounted steam trap 1 is working normally; when the temperature difference before and after the shaft-mounted steam trap 1 is ≥3℃; or the inlet pressure of the shaft-mounted fan is greater than -4.5kPa, and the fluctuation amplitude is greater than 1kPa; or the condensate flow is abnormal, LED indicator 4 will light up yellow to indicate that the shaft-mounted steam trap 1 is blocked and the filter screen should be cleaned; when any detection unit of the detection data is abnormal or the data is obviously abnormal, LED indicator 4 will light up red, and maintenance should be contacted for troubleshooting.

[0078] Combination Figure 3 Another aspect of the present invention provides a control method for a monitoring system of a shaft-mounted drain 1, comprising:

[0079] Collect the operating data of shaft-mounted steam trap 1. The operating data includes the inlet and outlet fluid temperature, inlet and outlet flow rate data, and shaft-mounted fan inlet pressure value of shaft-mounted steam trap 1.

[0080] Based on the operating data, the operating conditions of the shaft-mounted steam trap 1 are judged using a preset data analysis model, and a judgment result is generated.

[0081] Based on the judgment results and operational data, corresponding control commands are generated using a pre-set hierarchical response library.

[0082] Execute the corresponding display actions according to the control instructions.

[0083] It should be understood that the specific embodiments described above are merely illustrative or explanatory of the principles of the invention and do not constitute a limitation thereof. Therefore, any modifications, equivalent substitutions, improvements, etc., made without departing from the spirit and scope of the invention should be included within the protection scope of the invention. Furthermore, the appended claims are intended to cover all variations and modifications falling within the scope and boundaries of the appended claims, or equivalent forms of such scope and boundaries.

Claims

1. A shaft-mounted steam trap monitoring system, characterized in that, The system includes a data acquisition module, a data processing module, a control module, and a display execution module, which are connected in sequence. The acquisition module is used to collect the operating data of the shaft-mounted steam trap, which includes the inlet and outlet fluid temperatures, inlet and outlet flow rates, and inlet pressure of the shaft-mounted fan. The data processing module is used to judge the operating condition of the shaft-mounted steam trap based on the operating data using a preset data analysis model, and generate a judgment result. The control module is used to generate corresponding control commands based on the judgment result and the running data, and on a preset hierarchical response library. The display execution module is used to execute corresponding display actions according to the control instructions.

2. The system according to claim 1, characterized in that, The acquisition module includes a temperature detection unit, a flow detection unit, and a pressure detection unit; The temperature detection units are respectively installed at the inlet and outlet of the shaft-mounted steam trap to collect the inlet temperature and outlet temperature. The flow detection units are respectively installed at the inlet and outlet of the shaft-mounted steam trap to collect the inlet flow and outlet flow. The pressure detection unit is located at the inlet of the shaft-driven blower and is used to collect the inlet pressure.

3. The system according to claim 2, characterized in that, The data processing module includes a data processing unit and a data analysis unit; The data processing unit is used to amplify and perform analog-to-digital conversion on the running data; The data analysis unit is used to compare and analyze the processed data with a preset data analysis model.

4. The system according to claim 2, characterized in that, The data analysis model is a multi-parameter joint analysis model based on temperature difference, pressure value, pressure fluctuation value and flow rate value. The data model includes the parameter range of normal operating condition, the parameter range of blocked operating condition, and the parameter range of fault operating condition.

5. The system according to claim 4, characterized in that, The normal operating condition parameter range includes a temperature difference value less than a preset temperature difference threshold, a pressure value between a first pressure threshold and a second pressure threshold, a pressure fluctuation value less than a fluctuation threshold, and a flow rate value between a first flow rate threshold and a second flow rate threshold. The blockage condition parameter range includes at least one of the following: temperature difference greater than or equal to a temperature difference threshold, pressure value exceeding the range between a first pressure threshold and a second pressure threshold, pressure fluctuation value greater than or equal to a fluctuation threshold, and flow rate value exceeding the range between a first flow rate threshold and a second flow rate threshold. The range of fault condition parameters includes abnormal parameters or a fault in any one of the temperature detection unit, the flow detection unit, and the pressure detection unit.

6. The system according to claim 5, characterized in that, The hierarchical response library includes: The first response level includes generating normal operation control commands when the data is within the normal operating condition parameter range; The second response level includes generating a warning-level control command when the data meets the range of congestion operating parameters; The third response level includes generating an emergency control command when the data meets the fault condition parameter range.

7. The system according to claim 6, characterized in that, The display execution module includes an indicator light group, which is used to display different colored light states according to the control command.

8. The system according to claim 1, characterized in that, The system also includes a communication module, which is connected to the control module and is used to communicate with the host computer, upload operating data and alarm information, and receive remote control commands.

9. The system according to claim 1, characterized in that, The system also includes a data storage module, which is connected to the control module and is used to store historical operating data, fault records, and operation logs.

10. A control method for a shaft-mounted drain monitoring system as described in any one of claims 1-9, characterized in that, The control method includes: Collect operating data of the shaft-mounted steam trap, including the inlet and outlet fluid temperatures, inlet and outlet flow rates of the shaft-mounted steam trap, and the inlet pressure of the shaft-mounted fan. Based on the operating data, the operating condition of the shaft-mounted steam trap is judged using a preset data analysis model, and a judgment result is generated. Based on the judgment results and operating data, corresponding control commands are generated using a preset hierarchical response library. The corresponding display action is executed according to the control command.

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