Condensate Drain Apparatus with Sensor-Controlled Valve
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Solution Overview
Problem
Conventional steam traps are not well suited for operation over varying pressure ranges and fail to provide data regarding the condensate being discharged, leading to inefficient condensate management in steam systems.
Innovation Solution
A condensate drain apparatus equipped with a valve, collection chamber, and sensor equipment that monitors thermodynamic properties to control the discharge of condensate, using a controller to regulate the valve based on temperature differences and flow rate calculations to ensure efficient separation and recycling of condensate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional mechanical steam traps are used, then condensate discharge is achieved, but operation over varying pressure ranges is not suitable and data regarding discharged condensate is not provided
Solution Approach 1:
The patent replaces conventional mechanical steam trap mechanisms with an electrically controlled valve system. The valve is controlled by a controller that receives signals from sensors monitoring thermodynamic properties (temperature, pressure), enabling the system to adapt to varying pressure ranges and provide data about condensate discharge conditions.
Solution Approach 2:
The system incorporates sensors that monitor thermodynamic properties of the fluid and provide feedback to the controller. The controller uses this feedback information to adjust valve operation, ensuring optimal performance across varying pressure ranges while simultaneously providing data regarding the condensate being discharged.
2Ease of operation
If mechanical ball float type traps are used, then automatic condensate discharge is achieved, but operation over varying pressure ranges is not suitable
Solution Approach 1:
The patent employs a dynamically controllable valve system that can adjust its operation in real-time based on monitored thermodynamic conditions. Unlike fixed mechanical ball float traps, this dynamic system adapts to varying pressure ranges by receiving sensor feedback and modifying valve opening/closing behavior accordingly, while maintaining automatic operation through controller automation.
Solution Approach 2:
The system changes operational parameters (valve timing, opening degree) based on detected thermodynamic parameter changes. The controller monitors temperature and pressure parameters and adjusts valve operation to maintain optimal condensate discharge performance across different pressure ranges, replacing the fixed mechanical response of ball float traps.
3Reliability
If steam traps prevent steam loss, then system dryness is maintained, but useful energy in condensate is lost
Solution Approach 1:
The controller uses feedback from temperature sensors to determine when condensate has been sufficiently cooled. By monitoring the temperature difference between incoming steam and collected condensate, the system can identify the optimal moment to open the valve for discharge, ensuring system dryness is maintained while capturing condensate that still contains useful thermal energy for recovery.
Solution Approach 2:
The system performs preliminary cooling of condensate in the collection chamber before discharge. By allowing condensate to cool and condense fully before valve opening, the system ensures complete separation from steam (maintaining dryness) while preserving the thermal energy in the condensed liquid for potential recovery and reuse in the steam system.
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
The solution effectively manages condensate discharge, preventing steam loss and maintaining system dryness, while allowing for the recycling of useful energy, with improved accuracy and adaptability across different pressure ranges.
Implementation Method 1
sensor equipment for monitoring a parameter relating to a thermodynamic property of the fluid upstream of the valve
Implementation Method 2
the controller is further configured to determine the quantity of condensate discharged from the collection volume using a flow rate calculation for a choked flow of vaporizing liquid
Implementation Method 3
a collection chamber configured to receive a multiphase fluid flow upstream of the valve comprising gaseous and condensate phases
Data Source
AI summary
A condensate drain apparatus including a valve for controlling discharge of condensate from the condensate drain apparatus; a collection chamber configured to receive a multiphase fluid flow upstream of the valve including gaseous and condensate phases, the collection chamber defining a collection volume for collecting the condensate to be discharged through the valve; sensor equipment for monitoring a parameter relating to a thermodynamic property of the fluid upstream of the valve; a controller configured to monitor the condensate collected in the collection chamber based on the monitored parameter, and to control the opening and closing of the valve to regulate the condensate collected in the collection chamber upstream of the valve; wherein the controller is further configured to determine the quantity of condensate discharged from the collection volume using a flow rate calculation for a choked flow of vaporizing liquid.