Blowpipe Condensate Removal With Electric Level Sensing Access
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Solution Overview
Problem
Existing blowcase systems face issues with mechanical floats and valves that fail due to corrosion and wear, require complex maintenance, and lack easy access for repairs, leading to high costs and safety concerns.
Innovation Solution
A blowpipe system using electrically actuated tuning fork sensors and valves, eliminating mechanical components, with a removable end cap for easy access and no need for pressure relief valves, allowing remote monitoring and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical level floats and pneumatic valves are used in the blowcase system, then the system can detect liquid levels and control gas flow, but the mechanical components are prone to corrosion, wear, and failure requiring frequent maintenance
Solution Approach 1:
The patent replaces mechanical level float sensors with capacitive level sensors that have no moving parts, eliminating mechanical wear and corrosion. The pneumatic control valves are replaced with electronically controlled solenoid valves, removing the need for mechanical linkages and reducing maintenance requirements.
Solution Approach 2:
The blowcase is designed with self-draining capability through strategically positioned drainage ports that allow condensate to exit automatically based on liquid level, eliminating the need for manual intervention or complex mechanical drainage systems.
2Reliability
If the blowcase is designed as a large pressure vessel per ASME standards, then it can collect sufficient condensate, but it requires safety pressure relief valves and certification that increase cost and complexity
Solution Approach 1:
The patent divides the blowcase into multiple smaller chambers or compartments, each capable of independent operation. This segmentation allows each chamber to be designed below the ASME pressure vessel threshold, eliminating the need for pressure relief valves and certification while maintaining total condensate collection capacity.
Solution Approach 2:
The blowcase incorporates dynamic pressure equalization ports that open only when pressure differential exceeds a threshold, allowing the system to operate without permanent pressure relief valves by dynamically responding to pressure conditions rather than requiring static relief mechanisms.
3Ease of operation
If the blowcase lacks an inspection port, then the vessel structure remains simple, but users cannot inspect or perform maintenance on the interior components
Solution Approach 1:
The patent extracts the inspection function from the main vessel structure by providing removable end caps or access panels that can be easily detached without cutting or permanent modification, allowing interior inspection and maintenance while maintaining structural integrity when closed.
Solution Approach 2:
The inspection access mechanism is nested within the existing blowcase structure, with removable end caps that integrate with the vessel walls, providing inspection capability without adding external complexity or requiring structural modifications.
4Ease of operation
If a three-way pneumatic valve with mechanical actuator is used, then the valve can control gas flow directions, but the mechanical switch and actuator are prone to wear and require pressurized gas supply
Solution Approach 1:
The patent replaces the mechanical three-way valve with an electronically controlled solenoid valve that uses electromagnetic fields to actuate the valve mechanism, eliminating mechanical linkages, switches, and actuators that are prone to wear and failure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances system reliability, reduces maintenance costs, and simplifies maintenance procedures by providing easy access and reducing the risk of mechanical failures.
Implementation Method 1
A high level tuning fork sensor 194 and a low level tuning fork sensor 196 are mounted to the blowpipe
Implementation Method 2
The pressurized gas evacuates, or 'blows down,' the blowcase of liquid
Data Source
AI summary
The disclosure provides a blowpipe assembly for removing at intervals liquid, such as pulled from a knockout assembly, having a three-way electrically operated valve, tuning fork level sensors, and access to the blowpipe interior.