Low-pressure steam pipe network drainage on-line monitoring device and method

Abstract

The invention discloses a low-pressure steam pipe network drainage on-line monitoring device and method.The low-pressure steam pipe network drainage on-line monitoring device comprises a drainage valve set, a temperature sensing module, a signal receiving and transmitting module and a monitoring module, and the temperature sensing module measures the temperature in front of a drainage valve and the temperature behind the drainage valve online in real time; an expected model is built in an alarm unit in the monitoring module, and the alarm unit compares and analyzes the change rule of the difference between the temperature in front of the drain valve, the temperature behind the drain valve and the real-time temperature with the expected change rule, so that the state of the drain valve is automatically monitored in an uninterrupted, real-time, online and automatic manner. Whether the drain valve of the low-pressure steam pipe network works normally or not can be quickly and effectively judged.

Description

Technical Field

[0001] This invention relates to the field of industrial equipment condition monitoring technology, and more specifically, to an online monitoring device and method for low-pressure steam pipeline condensate. Background Technology

[0002] In industries such as chemical, textile, and food processing, steam pipeline networks are core energy transmission systems. During use, steam releases latent heat and condenses into water. This condensate must be discharged from the system promptly and effectively through steam traps. If a steam trap fails (e.g., due to blockage or leakage leading to direct steam discharge), it can cause water hammer, damaging pipeline equipment, wasting energy, and degrading steam quality.

[0003] Low-pressure steam pipelines (typically referring to pressures below 1.0 MPa) are more prone to steam trap failures due to significant pressure fluctuations. Currently, monitoring the condition of steam traps mainly relies on regular manual inspections, using methods such as listening, touching, or portable detectors. This approach has significant drawbacks: monitoring is not timely and cannot detect sudden malfunctions; inspection cycles are long, leading to delayed fault detection; reliance on personnel experience makes accurate judgment difficult to guarantee; and labor costs are high, resulting in low efficiency.

[0004] Prior art 1 (application number: 202021884778.0, application date: 2020.09.01) discloses an online monitoring system for leakage and blockage of steam traps. Specifically, it discloses that three temperature detectors are installed on the steam pipe, condensate tank, and outside the steam trap. The temperature sensors outside the steam trap are not connected to the steam trap inlet and outlet. Temperature data is analyzed through a distributed control system. If a leak occurs, an audible and visual alarm can be triggered. However, in actual use, the actual temperature of the steam trap inlet and outlet cannot be measured, so it is impossible to accurately determine whether the steam trap is faulty. At the same time, the audible and visual alarms require personnel to actually check the situation before the fault can be identified, and real-time automatic monitoring cannot be fully realized.

[0005] Prior art 2 (application number: 202411936738.9, application date: 2024.12.26) discloses an Internet-based steam pipeline drainage monitoring and diagnostic system. It collects pipeline pressure, temperature, water hardness, drainage outlet water flow images, and scale images, and transmits the data to a cloud diagnostic module via the Internet. It calculates the drainage probability by combining the pressure and temperature influence values ​​and determines whether drainage is needed. The calculation process is complex, and it does not specify where in the pipeline the temperature and pressure are collected. It may require shutdown or hot work to collect data, making the operation complicated and unable to achieve automatic online monitoring.

[0006] Therefore, the following technical problems urgently need to be solved in this field: 1. How to achieve real-time, online, and automatic monitoring of the working status of steam traps; 2. How to accurately diagnose the fault types of steam traps; 3. How to collect steam trap temperature data without stopping operation. Summary of the Invention

[0007] In view of this, the present invention provides an online monitoring device and method for low-pressure steam pipeline condensate, which solves the following problems: 1. How to achieve real-time, online and automatic monitoring of the working status of condensate traps; 2. How to accurately diagnose the fault type of condensate traps; 3. How to collect condensate trap temperature data without stopping operation.

[0008] This invention provides an online monitoring device for condensate draining in low-pressure steam pipelines, which includes: a condensate drain valve assembly, a temperature sensing module, a signal transceiver module, and a monitoring module.

[0009] The low-pressure steam pipeline network includes: a steam pipe and a condensate recovery pipe, wherein one end of the steam pipe is connected to one end of the condensate recovery pipe and a steam trap assembly is provided at the connection point;

[0010] The steam trap assembly includes: a front shut-off valve, a steam trap, and a rear shut-off valve arranged sequentially along the medium flow direction in the low-pressure steam pipeline network; the front shut-off valve is located at the inlet of the condensate recovery pipe; the rear shut-off valve is located on the condensate recovery pipe; and the steam trap is located between the front shut-off valve and the rear shut-off valve.

[0011] The input terminal of the temperature sensing module includes a first measuring point and a second measuring point. The first measuring point is connected to the inlet pipe of the steam trap, and the second measuring point is connected to the outlet pipe of the steam trap.

[0012] The input terminal of the signal transceiver module is communicatively connected to the output terminal of the temperature sensing module; the signal transceiver module includes: a gateway and a pass-through unit, the temperature sensing module transmits data to the gateway, and the pass-through unit transmits data to the monitoring module;

[0013] The input terminal of the monitoring module is communicatively connected to the output terminal of the signal transceiver module. The monitoring module includes an alarm unit, which constructs a predictive model. This model includes the expected changes in the temperature before, after, and between the steam trap and the steam trap within one operating cycle. The expected changes are described as sawtooth or pulse-like periodic fluctuation curves. The expected changes include: when the steam trap is closed, the expected temperature difference before and after the steam trap gradually increases; when the steam trap is open, the expected temperature after the steam trap gradually increases, and the expected temperature difference before and after the steam trap suddenly decreases. The alarm unit compares and analyzes the changes in the temperature before, after, and real-time temperature difference with the expected changes.

[0014] If the real-time temperature difference matches the expected change pattern, the steam trap is working normally; if the real-time temperature difference is 5℃-10℃ lower than the expected change pattern, the steam trap is leaking; if the real-time temperature difference is higher than 60℃-100℃ and there is no periodic fluctuation, the steam trap is blocked; if the periodic temperature rise characteristic of the temperature data after the steam trap disappears, the steam trap is blocked or leaking.

[0015] If the drain valve is blocked or leaking, the alarm unit sends a leak or blockage alarm signal to the user.

[0016] Optionally, the temperature sensing module is a wireless dual-point temperature sensor, which can be a clamp-mounted temperature sensor or a patch-mounted temperature sensor.

[0017] Optionally, along the extension direction of the steam pipe, the distance between the first measuring point or the second measuring point and the steam trap is 10 cm to 20 cm.

[0018] Secondly, the present invention also provides an online monitoring method for condensate drainage in low-pressure steam pipelines, used in the aforementioned online monitoring device for condensate drainage in low-pressure steam pipelines, comprising the following steps:

[0019] An expected model is constructed within the alarm unit. This model includes the expected changes in the temperature before, after, and between the steam trap and the steam trap within one working cycle. The expected changes are a sawtooth or pulse-like periodic fluctuation curve. The expected changes include: when the steam trap is closed, the expected temperature difference between the steam trap and the steam trap gradually increases; when the steam trap is open, the expected temperature after the steam trap gradually increases, and the expected temperature difference between the steam trap and the steam trap suddenly decreases.

[0020] The temperature sensing module collects temperature data before and after the steam trap.

[0021] The collected temperature data before and after the steam trap are transmitted to the monitoring module via the signal transceiver module.

[0022] In the monitoring module, the alarm unit dynamically compares the real-time temperature difference between the temperature data before and after the steam trap with the expected change pattern:

[0023] If the real-time temperature difference matches the expected change pattern, the steam trap is working normally; if the real-time temperature difference is 5℃-10℃ lower than the expected change pattern, the steam trap is leaking; if the real-time temperature difference is higher than 60℃-100℃ and there is no periodic fluctuation, the steam trap is blocked; if the periodic temperature rise characteristic of the temperature data after the steam trap disappears, the steam trap is blocked or leaking.

[0024] If the drain valve is blocked or leaking, the alarm unit sends a leak or blockage alarm signal to the user.

[0025] Compared with the prior art, the online monitoring device and method for low-pressure steam pipeline condensate provided by the present invention achieves at least the following beneficial effects:

[0026] 1. The low-pressure steam pipeline condensate online monitoring device provided by the present invention includes: a condensate valve group, a temperature sensing module, a signal transceiver module, and a monitoring module; by measuring the temperature data before and after the condensate valve through the temperature sensing modules set at both ends of the condensate valve, the device can realize uninterrupted real-time online and automatic monitoring of the working status of the condensate valve 24 / 7.

[0027] 2. In actual use, the alarm unit built based on the working mechanism of the steam trap can effectively distinguish between normal operating conditions and fault conditions by real-time monitoring and analysis of the temperature data before and after the steam trap and the difference between the real-time data and the expected model built internally. Thus, it can issue early warnings in the early stage of fault occurrence or performance degradation stage to avoid equipment damage.

[0028] 3. This device uses a wireless temperature sensor that can be directly installed on existing pipelines without stopping work or using open flames, and without requiring complex modifications to the existing pipelines. It is quick to install and can achieve real-time acquisition of steam trap temperature data without interrupting work.

[0029] 4. The low-pressure steam pipeline condensate online monitoring device and method of the present invention can significantly reduce the workload and frequency of manual inspection through automatic online monitoring, thereby reducing labor costs.

[0030] Of course, any product implementing this invention does not necessarily need to achieve all of the technical effects described above at the same time.

[0031] Other features and advantages of the invention will become clear from the following detailed description of exemplary embodiments of the invention with reference to the accompanying drawings. Attached Figure Description

[0032] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments of the invention and, together with their description, serve to explain the principles of the invention.

[0033] Figure 1 This is a schematic diagram of the structure of an online monitoring device for low-pressure steam pipeline condensate provided by the present invention;

[0034] Figure 2 This is a flowchart of an online monitoring method for condensate drainage in low-pressure steam pipelines provided by the present invention;

[0035] Figure 3 This is a temperature curve within the hydrophobic period;

[0036] 1-Steam pipe, 2-Condensate recovery pipe, 10-Drain valve assembly, 11-Front shut-off valve, 12-Drain valve, 13-Rear shut-off valve, 20-Temperature sensing module, 30-Signal transceiver module, 40-Monitoring module. Detailed Implementation

[0037] Various exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. It should be noted that, unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of the invention.

[0038] The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the invention or its application or use.

[0039] Techniques, methods, and equipment known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and equipment should be considered part of the specification.

[0040] In all the examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values.

[0041] It should be noted that similar labels and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be discussed further in subsequent figures.

[0042] Example 1

[0043] Reference Figure 1 The present invention provides an online monitoring device for condensate drainage in a low-pressure steam pipeline network, which is used in a low-pressure steam pipeline network and includes: a condensate drain valve group 10, a temperature sensing module 20, a signal transceiver module 30 and a monitoring module 40.

[0044] The low-pressure steam pipeline network includes: a steam pipe 1 and a condensate recovery pipe 2, one end of the steam pipe 1 is connected to one end of the condensate recovery pipe 2 and a steam trap assembly 10 is installed at the connection point;

[0045] The steam trap assembly 10 includes a front shut-off valve 11, a steam trap 12, and a rear shut-off valve 13 arranged sequentially along the medium flow direction in the low-pressure steam pipeline network. The front shut-off valve 11 is located at the inlet of the condensate recovery pipe 2; the rear shut-off valve 13 is located on the condensate recovery pipe 2; and the steam trap 12 is located between the front shut-off valve 11 and the rear shut-off valve 13.

[0046] The input terminal of the temperature sensing module 20 includes a first measuring point and a second measuring point. The first measuring point is connected to the inlet side pipe of the steam trap 12, and the second measuring point is connected to the outlet side pipe of the steam trap 12.

[0047] The input terminal of the signal transceiver module 30 is communicatively connected to the output terminal of the temperature sensing module 20. The signal transceiver module 30 includes a gateway and a transparent transmission unit. The temperature sensing module 20 transmits data to the gateway, and the gateway transmits the data to the monitoring module 40 through the network.

[0048] The input terminal of the monitoring module 40 is communicatively connected to the output terminal of the signal transceiver module 30. The monitoring module 40 includes an alarm unit, which constructs a prediction model. The prediction model includes the expected change patterns of the temperature before the steam trap 12, the temperature after the steam trap 12, and the temperature difference before and after the steam trap 12 within one steam trap cycle. The expected change patterns are sawtooth or pulse-shaped periodic fluctuation curves. The expected change patterns include: when the steam trap 12 is closed, the expected temperature difference before and after the steam trap 12 gradually increases; when the steam trap 12 is open, the expected temperature after the steam trap gradually increases, and the expected temperature difference before and after the steam trap 12 suddenly decreases. The alarm unit compares and analyzes the change patterns of the temperature before the steam trap 12, the temperature after the steam trap 12, and the real-time temperature difference with the expected change patterns. When the real-time temperature difference deviates from the expected change patterns, an alarm message is generated and output.

[0049] Specifically, refer to Figure 1 The present invention provides an online monitoring device for condensate drainage in a low-pressure steam pipeline network, which is used in a low-pressure steam pipeline network and includes: a condensate drain valve group 10, a temperature sensing module 20, a signal transceiver module 30 and a monitoring module 40.

[0050] The low-pressure steam pipeline network includes: a steam pipe 1 and a condensate recovery pipe 2, one end of the steam pipe 1 is connected to one end of the condensate recovery pipe 2 and a steam trap assembly 10 is installed at the connection point;

[0051] The steam trap assembly 10 includes a front shut-off valve 11, a steam trap 12, and a rear shut-off valve 13 arranged sequentially along the medium flow direction in the low-pressure steam pipeline network. The front shut-off valve 11 is located at the inlet of the condensate recovery pipe 2; the rear shut-off valve 13 is located on the condensate recovery pipe 2; and the steam trap 12 is located between the front shut-off valve 11 and the rear shut-off valve 13.

[0052] It should be noted that the steam trap assembly 10 is a standard configuration already present in the steam pipe network 1, including a front shut-off valve 11, a steam trap 12, and a rear shut-off valve 13. This invention expands upon existing equipment, requiring no complex modifications to existing pipelines, allowing for quick installation, and simultaneously enhancing functionality.

[0053] It should be noted that the shut-off valve in this embodiment is model J41W-16PDN15 or DN20, and can be installed using a flange. The steam trap is a mechanical steam trap or an inverted bucket steam trap.

[0054] The input terminal of the temperature sensing module 20 includes a first measuring point and a second measuring point. The first measuring point is connected to the inlet side pipe of the steam trap 12, and the second measuring point is connected to the outlet side pipe of the steam trap 12.

[0055] In some optional embodiments, the temperature sensing module 20 is a wireless dual-point temperature sensor, which can be a clamp-mounted temperature sensor or a patch-mounted temperature sensor.

[0056] It should be noted that the temperature sensing module 20 uses a wireless, dual-measuring-point, clamp-mounted or patch-mounted temperature sensor. The clamp-mounted sensor is directly fixed to the pipe surface with a metal clamp, eliminating the need for drilling or welding, and reducing installation time by more than 50% compared to other temperature sensors that require plugging. It is suitable for equipment already in operation (such as steam pipelines), avoiding downtime losses due to modifications. The clamp tightness is adjustable, allowing the sensor to move flexibly on the equipment surface, facilitating optimization of the temperature measurement point position. The patch-mounted sensor is typically less than 3mm thick and can be directly pasted onto the equipment surface, saving space. It supports curved surface pasting and is suitable for irregularly shaped equipment.

[0057] In some alternative embodiments, the distance between the first or second measuring point and the steam trap 12 along the extension direction of the steam pipe 1 is 10 cm to 20 cm.

[0058] It should be noted that the distance between the first or second measuring point and the steam trap 12 is set between 10 cm and 20 cm. The first measuring point is tightly fitted to the inlet pipe of the steam trap 12 with a metal clamp to measure the temperature before the steam trap. The second measuring point is installed in the same manner on the outlet pipe of steam trap 12 to measure the temperature after the steam trap. It enables synchronous monitoring of temperature at critical locations, and the installation process requires no open flame or production stoppage, thus greatly improving the ease of installation.

[0059] The input terminal of the signal transceiver module 30 is communicatively connected to the output terminal of the temperature sensing module 20. The signal transceiver module 30 includes a gateway and a transparent transmission unit. The temperature sensing module 20 transmits data to the gateway, and the gateway transmits the data to the monitoring module 40 through the network.

[0060] It should be noted that the signal transceiver module 30 includes a field gateway and a pass-through module. The temperature sensor sends data to the gateway via near-field wireless communication protocols such as ZigBee and LoRa, and the gateway then passes the data through to the remote monitoring module 40 via 4G / 5G or Ethernet.

[0061] The input terminal of the monitoring module 40 is communicatively connected to the output terminal of the signal transceiver module 30. The monitoring module 40 includes an alarm unit, which monitors the changes in the temperature before and after the steam trap 12 and the temperature difference before and after the steam trap during the working cycle. The alarm unit analyzes the changes in the temperature before and after the steam trap and the temperature difference before and after the steam trap and compares them with the expected changes. When the real-time temperature data deviates from the expected changes, an alarm message is generated and output.

[0062] The alarm unit dynamically compares the real-time temperature difference between the temperature data before and after the steam trap with the expected change pattern.

[0063] If the real-time temperature difference matches the expected change pattern, then the steam trap 12 is working normally; if the real-time temperature difference is 10℃-15℃ lower than the expected change pattern, then the steam trap 12 is leaking; if the real-time temperature difference is equal to the difference between the temperature data before the steam trap and the ambient temperature and there is no periodic fluctuation, then the steam trap 12 is blocked; if the periodic temperature rise characteristic of the temperature data after the steam trap disappears, then the steam trap 12 is blocked or leaking.

[0064] If the steam trap 12 is blocked or leaking, the alarm unit will send a leak or blockage alarm signal to the user.

[0065] It should be noted that monitoring module 40 is a programmable logic controller (PLC) system or a distributed control system (DCS). A PLC is a microprocessor-based digital electronic system designed for industrial environments. It executes logic operations, sequential control, timing and counting instructions through programmable memory to achieve automated control of mechanical equipment or production processes. Its core functions include: replacing traditional relays to achieve on / off control; executing actions according to preset steps using built-in timers / counters for time or frequency control (such as monitoring equipment running time); supporting analog input / output (such as temperature and pressure sensor signal processing); and achieving closed-loop control through PID algorithms. A typical PLC uses a modular, single-unit structure, including a CPU module, I / O module, power supply module, programmer, and communication module. The CPU module executes user programs, monitors input / output status, performs logical judgments, and processes data. The I / O module connects to external devices, such as sensors, to achieve signal conversion. The power supply module provides stable power to the system. The programmer is used for program writing, debugging, and monitoring (achieved through dedicated software or handheld devices). The communication module supports protocols such as Ethernet and PROFIBUS to enable device networking and remote monitoring.

[0066] DCS (Distributed Control System) is a network-based control system that distributes control functions to multiple nodes (such as sensors, actuators, and PLCs) through distributed computing and communication technologies, enabling efficient control of large-scale continuous processes. Its core functions include: real-time monitoring and precise adjustment of analog quantities such as temperature, pressure, and flow; multi-variable optimization and fault diagnosis through a hierarchical structure; and support for storing process data in a historical database, providing a basis for production optimization and decision-making. DCS employs a distributed structure, with typical components including: process control stations, operator stations, engineer stations, a communication network, and a historical database. Process control stations are distributed across the field, executing loop control; operator stations provide a human-machine interface for process monitoring and manual intervention; and engineer stations are used for system configuration, programming, and maintenance. The communication network uses industrial Ethernet or fieldbus to connect nodes and achieve high-speed data transmission; the historical database stores process data long-term, supporting trend analysis and report generation. DCS ensures continuous system operation through redundancy design and uses standardized protocols to support integration with third-party equipment or systems.

[0067] It should be noted that the alarm unit is a software algorithm unit deployed on the platform to which the monitoring module 40 belongs. Its core logic is based on the temperature data before the steam trap. Temperature data before the steam trap and the real-time temperature difference before and after the steam trap ( Pattern recognition of time-series data, including a closing period and an opening period in a normal condensate drain cycle; during the closing period, condensate drain valve 12 is closed, and the temperature data before the condensate drain valve... Temperature data after steam trap, close to steam temperature The temperature drops slowly due to heat dissipation into the environment; real-time temperature difference. The temperature gradually increases. During the opening phase, condensate accumulates to a certain level, and steam trap 12 opens, allowing high-temperature condensate to flow through instantly, thus increasing the temperature data after the steam trap. Rapidly rising, real-time temperature difference A sudden decrease, and this cycle repeats, as shown on the data curve. It exhibits periodic fluctuations in a sawtooth or pulse-like pattern. A judgment rule is constructed within the alarm unit; if... If the temperature remains high (above 60℃-100℃) for an extended period (e.g., more than 30 minutes) without any drop pulse, it is determined that steam trap 12 is blocked. If it remains at a low level for an extended period (e.g., below 10°C), and Continue to approach If so, it is determined that steam trap 12 is leaking and steam is being discharged directly.

[0068] If the fluctuation period is abnormally prolonged or shortened, the performance of the steam trap 12 will degrade. Once the alarm unit detects the above abnormal pattern, it will immediately push alarm information through the operator interface of the monitoring module 40, SMS, email, etc. The alarm information can display the collected abnormal data to facilitate timely handling by staff.

[0069] Reference Figure 3 The temperature and temperature difference of the hydrophobic cycle in this example are explained. The horizontal axis represents time t, starting from the cycle start point. Initially, a cycle is completed, namely the drainage cycle, which includes the opening points of drain valve 12. and steam trap 12 valve closing point Until the start of the next cycle, Indicates the start of the loop; This is the opening point of steam trap 12, at which point the temperature difference... Temperature data before the steam trap Temperature data after steam trap All showed a sharp increase; For the closing point of steam trap 12, the temperature data after the steam trap is... At this point, the temperature begins to drop slowly, entering the preparation phase for the next cycle. The vertical axis represents temperature or temperature difference. The value is upward, indicating an increasing direction. (Peak value) represents the temperature difference. The curve is sawtooth-shaped, exhibiting narrow fluctuations at high levels, at the valve opening point. The price rose sharply. (Saturation temperature) represents the temperature data curve before the steam trap, which shows a sawtooth pattern with small fluctuations at high temperatures, also at the valve opening point. The price rose sharply. (peak) and (Low position) indicates the temperature data curve after the steam trap, which is also sawtooth-shaped, but with larger fluctuations at low temperatures. This is at the valve opening point of steam trap 12. The temperature rose sharply, then at the valve closure point of steam trap 12. Then it slowly decreased ( to (gradual descent between periods). Figure 3 Different curves are used to illustrate the temperature data before the steam trap 12 during the opening and closing processes. and temperature difference The temperature rises rapidly with slight fluctuations when steam trap 12 is opened, while the temperature data downstream of the steam trap... The temperature rises sharply when steam trap 12 is opened and slowly decreases after it is closed, with large fluctuations in temperature.

[0070] It is understood that this invention constructs a complete online monitoring device for low-pressure steam pipeline network condensate through an automated process of "sensing-transmission-analysis-early warning," which significantly improves the intelligence level and safe operation capability of steam pipeline network management.

[0071] It is understood that the present invention provides an online monitoring device for low-pressure steam pipeline condensate, which includes: a condensate valve group 10, a temperature sensing module 20, a signal transceiver module 30, and a monitoring module 40; by measuring the temperature data before and after the condensate valve 12 by the temperature sensing module 20 set at both ends of the condensate valve 12, the device realizes 7x24-hour uninterrupted automatic monitoring of the status of the condensate valve 12, overcoming the intermittent shortcomings of manual inspection. The alarm unit, built based on the working mechanism of steam trap 12, effectively distinguishes between normal operating conditions and fault states by real-time monitoring and analysis of the temperature data before and after the steam trap and the difference between the real-time data and the data, and comparing it with the expected model built internally. It has high accuracy and low false alarm rate, and issues timely warnings in the early stage of fault occurrence or performance degradation stage, supports preventive maintenance, and avoids equipment damage and energy waste. The device uses a wireless temperature sensor to be directly installed on the existing pipeline without the need for complex modifications to the existing pipeline, and the installation is quick. The online monitoring device and method for low-pressure steam network condensate can significantly reduce the workload and frequency of manual inspection, reduce labor costs, and improve overall operation and maintenance efficiency.

[0072] Example 2

[0073] The present invention also provides a method for online monitoring of condensate in a low-pressure steam pipeline network using the online monitoring device for condensate in a low-pressure steam pipeline network according to Embodiment 1, comprising the following steps:

[0074] S1: An expected model is constructed within the alarm unit; the expected model includes the expected change patterns of the temperature before the steam trap, the temperature after the steam trap, and the temperature difference before and after the steam trap within one working cycle. The expected change patterns include: when the steam trap is closed, the expected temperature difference before and after the steam trap gradually increases; when the steam trap is open, the expected temperature after the steam trap gradually increases, and the expected temperature difference before and after the steam trap suddenly decreases.

[0075] S2: Temperature sensing module 20 collects temperature data before and after the steam trap;

[0076] S3: The collected temperature data before and after the steam trap are transmitted to the monitoring module 40 via the signal transceiver module 30.

[0077] S4: In the monitoring module 40, the alarm unit dynamically compares the real-time temperature difference between the temperature data before and after the steam trap with the expected change pattern.

[0078] If the real-time temperature difference matches the expected change pattern, then the steam trap 12 is working normally; if the real-time temperature difference is 10℃-15℃ lower than the expected change pattern, then the steam trap 12 is leaking; if the real-time temperature difference is equal to the difference between the temperature data before the steam trap and the ambient temperature and there is no periodic fluctuation, then the steam trap 12 is blocked; if the periodic temperature rise characteristic of the temperature data after the steam trap disappears, then the steam trap 12 is blocked or leaking.

[0079] S5: If the steam trap 12 is blocked or leaking, the alarm unit will send a leak or blockage alarm signal to the user.

[0080] Specifically, a predictive model is first constructed within the alarm unit. In this model, the steam trap 12 operates within a single cycle (drainage cycle), including a closing phase and an opening phase. During the opening phase, condensate accumulates to a certain level, causing the steam trap 12 to open and allowing high-temperature condensate to flow through instantaneously. This causes a sharp rise in temperature downstream of the predicted steam trap, resulting in a sudden decrease in the temperature difference before and after the predicted steam trap. This cycle repeats periodically, manifesting on the data curve as a sawtooth or pulse-like periodic fluctuation in the temperature difference before and after the predicted steam trap. The temperature sensing module 20 collects the temperature data upstream of the steam trap through the first measuring point. Temperature data after steam trap and the temperature data before the steam trap Temperature data after steam trap The signal is transmitted to the monitoring module 40 via the signal transceiver module 30; the monitoring module 40 receives the temperature data before the drain valve. Temperature data after steam trap Then, the alarm unit analyzes the temperature data before the steam trap. Temperature data after steam trap And obtain the real-time temperature difference value Dynamically compare with expected patterns of change;

[0081] If the real-time temperature difference matches the expected change pattern, steam trap 12 is functioning normally. If the real-time temperature difference is 10℃-15℃ lower than the expected change pattern, steam trap 12 is leaking. If the ambient temperature of the pipeline network is high, the difference between the real-time temperature difference and the expected change pattern can be adjusted to 12℃-15℃. If the ambient temperature is low, the difference between the real-time temperature difference and the expected change pattern can be lowered to 5-8℃. If the real-time temperature difference is higher than 60℃-100℃ and there is no periodic fluctuation, steam trap 12 is blocked. If the steam design temperature is high (e.g., 160℃-180℃), and the real-time temperature difference is higher than 90-100℃ and there is no periodic fluctuation, steam trap 12 is blocked. If the design temperature is low (e.g., 100-120℃), and the real-time temperature difference is higher than 60-70℃ and there is no periodic fluctuation, steam trap 12 is blocked. The threshold needs to be linked to the duration, which is generally more than 30 minutes to avoid false alarms triggered by short-term fluctuations. The periodic temperature rise characteristic of the temperature data after the steam trap disappears, indicating that the steam trap 12 is blocked or leaking. The alarm unit recognizes the above abnormal mode and immediately pushes alarm information through the operator interface of the monitoring module 40, SMS, email and other means.

[0082] It is understood that the present invention provides an online monitoring method for condensate drains in a low-pressure steam pipeline network. The online monitoring device for condensate drains in a low-pressure steam pipeline network includes: a condensate drain valve group 10, a temperature sensing module 20, a signal transceiver module 30, and a monitoring module 40. By measuring the temperature data before and after the condensate drain valve 12 through the temperature sensing modules 20 set at both ends of the condensate drain valve 12, the 24 / 7 uninterrupted automatic monitoring of the status of the condensate drain valve 12 is realized, overcoming the intermittent shortcomings of manual inspection. The alarm unit, built based on the working mechanism of steam trap 12, effectively distinguishes between normal operating conditions and fault states by real-time monitoring and analysis of the temperature data before and after the steam trap and the difference between the real-time data and the data, and comparing it with the expected model built internally. It has high accuracy and low false alarm rate, and issues timely warnings in the early stage of fault occurrence or performance degradation stage to avoid equipment damage and energy waste. The device uses a wireless temperature sensor that can be directly installed on the existing pipeline without complex modifications to the existing pipeline, making installation quick. The online monitoring method for steam network condensate of the present invention can significantly reduce the workload and frequency of manual inspection, reduce labor costs, improve overall operation and maintenance efficiency, and significantly improve the intelligence level and safe operation capability of steam network management.

[0083] While specific embodiments of the invention have been described in detail by way of examples, those skilled in the art should understand that the examples are for illustrative purposes only and not intended to limit the scope of the invention. Those skilled in the art should understand that modifications can be made to the above embodiments without departing from the scope and spirit of the invention. The scope of the invention is defined by the appended claims.

Claims

1. An online monitoring device for condensate drainage in low-pressure steam pipelines, characterized in that, For use in low-pressure steam pipeline networks, including: steam trap assembly, temperature sensing module, signal transceiver module and monitoring module; The low-pressure steam pipeline network includes: a steam pipe and a condensate recovery pipe, wherein one end of the steam pipe is connected to one end of the condensate recovery pipe and a steam trap assembly is provided at the connection point; The steam trap assembly includes: a front shut-off valve, a steam trap, and a rear shut-off valve arranged sequentially along the medium flow direction in the low-pressure steam pipeline network; the front shut-off valve is located at the inlet of the condensate recovery pipe; the rear shut-off valve is located on the condensate recovery pipe; and the steam trap is located between the front shut-off valve and the rear shut-off valve. The input terminal of the temperature sensing module includes a first measuring point and a second measuring point. The first measuring point is connected to the inlet pipe of the steam trap, and the second measuring point is connected to the outlet pipe of the steam trap. The input terminal of the signal transceiver module is communicatively connected to the output terminal of the temperature sensing module; the signal transceiver module includes: a gateway and a pass-through unit, the temperature sensing module transmits data to the gateway, and the pass-through unit transmits data to the monitoring module; The input terminal of the monitoring module is communicatively connected to the output terminal of the signal transceiver module. The monitoring module includes an alarm unit, which constructs a predictive model. This model includes the expected changes in the temperature before, after, and between the steam trap and the steam trap within one operating cycle. The expected changes are described as sawtooth or pulse-like periodic fluctuation curves. The expected changes include: when the steam trap is closed, the expected temperature difference before and after the steam trap gradually increases; when the steam trap is open, the expected temperature after the steam trap gradually increases, and the expected temperature difference before and after the steam trap suddenly decreases. The alarm unit compares and analyzes the changes in the temperature before, after, and real-time temperature difference with the expected changes. If the real-time temperature difference matches the expected change pattern, the steam trap is working normally; if the real-time temperature difference is 5℃-10℃ lower than the expected change pattern, the steam trap is leaking; if the real-time temperature difference is higher than 60℃-100℃ and there is no periodic fluctuation, the steam trap is blocked; if the periodic temperature rise characteristic of the temperature data after the steam trap disappears, the steam trap is blocked or leaking. If the drain valve is blocked or leaking, the alarm unit sends a leak or blockage alarm signal to the user.

2. The online monitoring device for low-pressure steam pipeline condensate according to claim 1, characterized in that, The temperature sensing module is a wireless dual-point temperature sensor, which can be either a clamp-mounted temperature sensor or a patch-mounted temperature sensor.

3. The online monitoring device for low-pressure steam pipeline condensate according to claim 1, characterized in that, Along the extension direction of the steam pipe, the distance between the first measuring point or the second measuring point and the steam trap is 10 cm to 20 cm.

4. A method for online monitoring of condensate drains in a low-pressure steam pipeline network, used in the online monitoring device for condensate drains in a low-pressure steam pipeline network as described in any one of claims 1 to 3, characterized in that, Including the following steps: An expected model is constructed within the alarm unit. This model includes the expected changes in the temperature before, after, and between the steam trap and the steam trap within one working cycle. The expected changes are a sawtooth or pulse-like periodic fluctuation curve. The expected changes include: when the steam trap is closed, the expected temperature difference between the steam trap and the steam trap gradually increases; when the steam trap is open, the expected temperature after the steam trap gradually increases, and the expected temperature difference between the steam trap and the steam trap suddenly decreases. The temperature sensing module collects temperature data before and after the steam trap. The collected temperature data before and after the steam trap are transmitted to the monitoring module via the signal transceiver module. In the monitoring module, the alarm unit dynamically compares the real-time temperature difference between the temperature data before and after the steam trap with the expected change pattern: If the real-time temperature difference matches the expected change pattern, the steam trap is working normally; if the real-time temperature difference is 5℃-10℃ lower than the expected change pattern, the steam trap is leaking; if the real-time temperature difference is higher than 60℃-100℃ and there is no periodic fluctuation, the steam trap is blocked; if the periodic temperature rise characteristic of the temperature data after the steam trap disappears, the steam trap is blocked or leaking. If the drain valve is blocked or leaking, the alarm unit sends a leak or blockage alarm signal to the user.

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