Float-Operated Condensate Pump Trap for Low Filling Heads
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Solution Overview
Problem
Conventional pressure-powered pumps and steam traps struggle to maintain process efficiency due to fluctuating upstream pressures, leading to condensate re-entry in heat exchangers, especially at low installation heights, and induce tensile loads in biasing members, affecting operational pressures.
Innovation Solution
A pumping and trapping device comprising a vessel with a float, float lever, connecting link, bell crank lever, biasing member, actuator link, and trap valve, configured to manage condensate and steam flow efficiently, using a double crank mechanism and non-return valves to prevent tensile load induction and optimize internal volume utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional pressure powered pumps are used to pump fluid from low upstream pressure zones, then pumping capability is provided, but the device cannot operate at small filling heads causing condensate to re-enter heat exchanger
Solution Approach 1:
The invention uses a dynamic float-operated mechanism with a bell crank lever that adapts to varying upstream pressures and small filling heads. The float rises with condensate level and dynamically actuates the bell crank lever to open the trap valve, enabling operation at small filling heads without condensate re-entry.
Solution Approach 2:
The device is self-actuating through buoyancy forces on the float. The float automatically rises with condensate level and triggers the discharge mechanism without external control, enabling reliable operation at small filling heads where conventional pumps fail.
2Ease of operation
If float and float lever are rigidly connected to allow float to rotate about fixed point, then trapping motion is enabled, but tensile load is induced in spring during trapping motion
Solution Approach 1:
Instead of the float directly rotating about a fixed point (which induces tensile load), the invention inverts the mechanism by using a bell crank lever where the float connects to one arm and the trap valve connects to the other. This inversion converts the trapping motion into a compressive action on the biasing member, eliminating tensile loads.
Solution Approach 2:
The rigid float-lever connection is segmented into separate components: the float, the connecting link, and the bell crank lever. This segmentation allows the trap valve to pivot independently about its own axis while the bell crank lever translates float motion into valve opening motion, preventing tensile load induction.
3Productivity
If snap action mechanism with extension spring is used for pumping fluid, then pumping function is provided, but more accommodation space is required
Solution Approach 1:
The invention merges the float-operated trapping mechanism with the pumping function into a single integrated device. The bell crank lever simultaneously controls trap valve opening and actuates the pumping action, eliminating the need for separate snap action mechanisms and reducing accommodation space.
Solution Approach 2:
The bell crank lever serves multiple functions: it translates float motion into trap valve opening, actuates the pumping mechanism, and controls steam inlet/outlet valves. This multi-functionality consolidates what would traditionally require separate components, reducing overall device volume.
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 device effectively removes condensate across varying pressure conditions without affecting process efficiency, is compact, easy to maintain, and increases per stroke discharge, while preventing tensile load induction in the biasing member, ensuring consistent operation even during stalling conditions.
Implementation Method 1
The float has an extension rigidly connected to the float. The float lever is pivotally connected to the support bracket and the extension.
Implementation Method 2
The bell crank lever is configured to compress the biasing member under influence of the connecting link when the float is displaced in an operative upward or downward direction.
Implementation Method 3
Fluctuating upstream pressure is often experienced by processes which use steam to heat the fluid present in heat exchangers
Data Source
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AI summary
The present disclosure envisages a pumping and trapping device (100) that removes condensate from a heat exchanger (200) even when upstream pressure in the device (100) is lesser than the downstream pressure. The device (100) comprises a float (1) operated mechanical linkage. The float (1) is displaceable with respect to condensate level within a vessel (102) of the device (100). The mechanical linkage is configured to selectively operate a steam inlet port (19) and a steam outlet port (20) configured on the vessel (102), thereby removing condensate accumulated within the vessel (102).