Floating ball type drain valve bypass control system based on ultrasonic liquid level monitoring
The float-type steam trap bypass system, which uses ultrasonic level monitoring and electric valve control, solves the problem of condensate surge during steam system start-up and shutdown, enabling rapid, high-flow-rate drainage and ensuring safe and efficient system operation.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-05-16
- Publication Date
- 2026-04-03
Smart Images
Figure CN224079981U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of steam pipeline drainage technology, and in particular to a float-type steam trap bypass control system based on ultrasonic liquid level monitoring. Background Technology
[0002] Steam traps are installed in piping systems heated by steam. Their function is to continuously discharge condensate from the steam pipes to the outside of the pipes under high temperature and high pressure conditions. This prevents excessive condensate buildup from causing water hammer in the steam pipes, which can lead to equipment damage and affect safe production. At the same time, timely drainage also ensures smooth steam flow, so as not to affect the normal operation and efficiency of the equipment.
[0003] Currently, existing float-type steam traps control the opening and closing of the valve by the rise and fall of the float with the water level. However, when the steam system starts up or stops or the parameters change suddenly, the surge in condensate volume may lead to insufficient drainage capacity of the main drain outlet, causing the following problems: (1) the water is impacted by high-speed steam, causing severe vibration of the pipeline; (2) the water obstructs the flow of steam and reduces the heat transfer efficiency; (3) long-term water accumulation corrodes the pipeline, and in extreme cases, it may cause the pipe to burst. Utility Model Content
[0004] To address the aforementioned issues, this application provides a float-type steam trap bypass control system based on ultrasonic level monitoring, which can monitor the condensate level inside the steam trap in real time and dynamically adjust the drainage flow rate, thus solving the problem of insufficient discharge of large instantaneous flow of condensate.
[0005] To achieve the objectives of this application, the following technical solution is provided:
[0006] This application provides a bypass control system for a float-type steam trap based on ultrasonic level monitoring, comprising: a steam trap body, an ultrasonic level gauge, a bypass steam trap pipe, and a control system;
[0007] The main body of the steam trap is equipped with a float, a valve seat and a main drain outlet. The float is a hollow sealing structure and directly serves as an opening and closing element, which moves with the rise and fall of the condensate level to fit or detach from the valve seat in order to control the opening and closing of the main drain outlet.
[0008] The ultrasonic level gauge is installed at the top center of the steam trap body and is used to monitor the height of the float in real time and output an electrical signal.
[0009] The bypass drain pipe is connected in parallel to the main drain outlet of the drain valve body, and an electric valve is installed on the bypass drain pipe;
[0010] The control system receives electrical signals from the ultrasonic level gauge. When the float height reaches a preset upper limit threshold, it controls the electric valve to open to increase the drainage flow. When the float height returns to the normal range, it closes the electric valve.
[0011] In one possible implementation, the ultrasonic level gauge is aligned vertically with the top of the float, and the real-time height of the float is calculated using the sound wave reflection time.
[0012] In one possible implementation, the diameter of the bypass drain pipe is larger than the diameter of the main drain outlet of the steam trap body, so as to provide a larger drainage volume when the electric valve is opened, and the drainage direction of the bypass drain pipe is consistent with the drainage direction of the steam trap body.
[0013] In one possible implementation, the control system includes a PLC controller with a built-in logic program, a preset dynamic threshold range for the float height, and automatic opening and closing of the electric valve.
[0014] In one possible implementation, the electric valve is an electric ball valve with a response time of ≤1 second.
[0015] The float-type steam trap bypass control system based on ultrasonic level monitoring provided in this application can monitor the float height in real time through an ultrasonic level gauge. When the liquid level rises abnormally, the bypass electric valve is automatically opened to improve drainage capacity and avoid water accumulation and water hammer risks in the pipeline. Attached Figure Description
[0016] The accompanying drawings are provided to further understand this application and form part of the specification. They are used together with the embodiments of this application to explain this application and do not constitute a limitation thereof.
[0017] Figure 1 This is a schematic diagram of the structure provided for an embodiment of this application;
[0018] Figure 2 Detailed flowchart provided for embodiments of this application;
[0019] In the diagram: 1. Steam trap body, 2. Float, 3. Valve seat, 4. Main drain outlet, 5. Ultrasonic level gauge, 6. Bypass drain pipe, 7. Electric valve, 8. Control system. Detailed Implementation
[0020] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.
[0021] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature; in the description of this application, unless otherwise stated, "multiple" means two or more.
[0022] Example
[0023] Figure 1-2 An embodiment of this application provides a bypass control system for a float-type steam trap based on ultrasonic level monitoring, comprising: a steam trap body 1, an ultrasonic level gauge 5, a bypass steam trap pipe 6, and a control system 8.
[0024] The steam trap body 1 contains a float 2, a valve seat 3, and a main drain port 4. The float 2 is a hollow sphere precision-ground from stainless steel, serving as both a float and an opening / closing element. It directly controls the opening and closing of the valve seat 3 through its own rising and falling motion. When condensate enters the steam trap body 1, the float 2 rises with the liquid level, separating from the valve seat 3 and opening the main drain port 4, allowing the condensate to drain through it. When condensate stops entering or the liquid level drops, the float 2 falls precisely under its own weight and the backflow of the medium, its bottom spherical surface directly contacting the sealing surface of the valve seat 3, thereby closing the main drain port 4 and forming a vapor seal. During this process, the float 2 requires no additional transmission mechanism, achieving adaptive opening and closing of the valve port through changes in liquid level.
[0025] The ultrasonic level gauge 5 is installed at the top center of the steam trap body 1, with its detection direction vertically downwards and aligned with the top of the float 2. The ultrasonic level gauge 5 monitors the liquid level height of the float 2 in real time by emitting sound waves and receiving the reflected signals from the float 2, and converts the signals into electrical signals for output.
[0026] A bypass drain pipe 6 is connected in parallel to the main drain outlet 4 of the drain valve body 1. The diameter of the bypass drain pipe 6 is larger than the diameter of the main drain outlet 4, and the drainage direction of the bypass drain pipe 6 is consistent with the drainage direction of the drain valve body 1. An electric valve 7 is installed on the bypass drain pipe 6. The electric valve 7 is a quick-opening butterfly valve with a response time of ≤1 second. When fully open, the flow rate of the bypass drain pipe 6 can reach at least twice the flow rate of the main drain outlet 4.
[0027] In one possible implementation, the control system 8 employs a PLC controller to receive the electrical signal from the ultrasonic level gauge 5 and preset the float 2 height threshold.
[0028] Upper limit threshold: Float 2 rises to 90% of the valve chamber height (triggers bypass opening);
[0029] Normal threshold: Float 2 is at 30%-80% of the valve cavity height (only the main drain port is working);
[0030] Lower threshold: Float 2 is below 20% of the valve chamber height (alarm indicates low liquid level abnormality).
[0031] Workflow:
[0032] Normal condensate drainage mode: When the condensate flow in the steam pipe is normal, float 2 floats at 50% of the valve chamber height, and the main drain port 4 opens and closes periodically to drain water. When the ultrasonic level gauge 5 detects that float 2 is within the normal range, the control system 8 keeps the electric valve 7 closed.
[0033] High-load conditions: When the steam system starts or the load suddenly increases, the condensate volume increases sharply, and the float 2 quickly rises to 90% of the valve chamber height. The ultrasonic level gauge 5 sends a signal to the control system 8 in real time, and the PLC controller immediately outputs a command to open the electric valve 7. At this time, the main drain 4 and the bypass drain pipe 6 drain simultaneously, increasing the total drainage volume to 2.5 times the normal level, quickly discharging excess condensate.
[0034] Recovery phase: When the liquid level drops to 60% of the valve chamber height, the control system 8 closes the electric valve 7, and the system resumes drainage only from the main drain port 4.
[0035] The beneficial effects of using the embodiments of this application are as follows:
[0036] 1. The system is designed with a bypass pipe connected in parallel to the main drain outlet, which automatically expands the capacity when the condensate flow is too large, ensuring system safety;
[0037] 2. The ultrasonic level gauge measures the float height non-contactly, providing accurate real-time monitoring and avoiding the problem of traditional mechanical structures being easily affected by dirt.
[0038] 3. Electric valves have a short response time, which can quickly adjust the drainage flow and prevent the liquid level from getting out of control;
[0039] 4. The float ball combines the functions of a float and an opening and closing element, directly controlling the opening and closing of the valve seat through changes in liquid level, reducing jamming failures, and is especially suitable for condensate containing impurities, thus reducing maintenance costs.
[0040] In the embodiments provided in this application, it should be understood that the disclosed systems, modules, and methods can be implemented in other ways. For example, the module embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces, or indirect coupling or communication connection between modules or units, and may be electrical, mechanical, or other forms.
[0041] The above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit it. This application is not limited to the exact structures described above and illustrated in the accompanying drawings, and it should not be considered that the specific implementation of this application is limited to these descriptions. For those skilled in the art, various changes and modifications made without departing from the concept of this application should be considered to fall within the protection scope of this application.
Claims
1. A bypass control system for a float-type steam trap based on ultrasonic liquid level monitoring, characterized in that, include: Steam trap body, ultrasonic level gauge, bypass drain pipe, control system; The main body of the steam trap is equipped with a float, a valve seat and a main drain outlet. The float is a hollow sealing structure and directly serves as an opening and closing element, which moves with the rise and fall of the condensate level to fit or detach from the valve seat in order to control the opening and closing of the main drain outlet. The ultrasonic level gauge is installed at the top center of the steam trap body and is used to monitor the height of the float in real time and output an electrical signal. The bypass drain pipe is connected in parallel to the main drain outlet of the drain valve body, and an electric valve is installed on the bypass drain pipe; The control system receives electrical signals from the ultrasonic level gauge. When the float height reaches a preset upper limit threshold, it controls the electric valve to open to increase the drainage flow. When the float height returns to the normal range, it closes the electric valve.
2. The bypass control system for a float-type steam trap based on ultrasonic liquid level monitoring according to claim 1, characterized in that, The ultrasonic level gauge is vertically aligned with the top of the float, and the real-time height of the float is calculated by the sound wave reflection time.
3. The bypass control system for a float-type steam trap based on ultrasonic liquid level monitoring according to claim 1, characterized in that, The bypass drain pipe has a diameter larger than the main drain outlet diameter of the steam trap body, which is used to provide a larger drainage volume when the electric valve is opened, and the drainage direction of the bypass drain pipe is consistent with the drainage direction of the steam trap body.
4. The bypass control system for a float-type steam trap based on ultrasonic liquid level monitoring according to claim 1, characterized in that, The control system includes a PLC controller with built-in logic program, preset dynamic threshold range of float height, and realizes automatic opening and closing of electric valve.
5. A bypass control system for a float-type steam trap based on ultrasonic liquid level monitoring according to claim 1, characterized in that, The electric valve is a quick-opening butterfly valve with a response time of ≤1 second.