Double Orifice Steam Trap for Variable Condensate Loads
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Solution Overview
Problem
Conventional float type steam traps are inefficient in handling high condensate loads and varying condensate loads, leading to oversized and costly installations, and fail to effectively vent air during startup, resulting in increased production times and corrosion.
Innovation Solution
A steam trap design featuring a chamber with a first and second orifice, controlled by a lever and link arrangement with a resilient element to dampen movement, allowing for selective discharge of condensate through both orifices, optimizing size and reducing bulk and cost, while effectively handling variable condensate loads and air venting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single orifice is used in conventional float type steam traps, then the device complexity is reduced, but the condensate discharge rate is insufficient for high and variable condensate loads
Solution Approach 1:
The single orifice is segmented into multiple orifices (first orifice and second orifice) with different sizes. The first orifice has a larger diameter for high condensate load discharge, while the second orifice has a smaller diameter for low condensate load discharge. This segmentation allows the steam trap to handle a wide range of condensate loads effectively without requiring an oversized single orifice.
Solution Approach 2:
The system dynamically switches between different orifices based on condensate load conditions. Through the lever and link arrangement with resilient element, the float position dynamically controls which orifice is active - the first orifice opens for high condensate loads, while the second orifice opens for low condensate loads. This dynamic adaptation optimizes discharge rate across varying operating conditions.
2Productivity
If a larger orifice is used to handle high condensate loads, then the condensate discharge rate is improved, but the steam trap size and installation bulk increase
Solution Approach 1:
Instead of using one large orifice that would require a bulky steam trap body, the discharge path is segmented into multiple orifices of different sizes. The first orifice (larger) and second orifice (smaller) are positioned in the base plate, allowing efficient condensate discharge without increasing the overall steam trap volume. The segmented approach maintains compact dimensions while achieving high discharge capacity when needed.
Solution Approach 2:
Different regions of the base plate have different orifice characteristics - the first orifice location provides larger diameter for high flow capacity, while the second orifice location provides smaller diameter for precise low flow control. This local differentiation of orifice quality allows the compact steam trap to handle varying condensate loads effectively without uniform size increase throughout the device.
3Speed
If the float lever mechanism moves quickly to open/close orifices, then the response time is reduced, but the wear and tear on mechanical components increases
Solution Approach 1:
A resilient element (spring) is incorporated into the link arrangement between the float lever and the orifice closing elements. This spring provides cushioning during the opening and closing operations, absorbing impact forces when the float rapidly moves to change orifice states. The resilient element reduces mechanical shock and wear on the lever, links, and orifice seats, thereby extending component life while maintaining rapid response capability.
Solution Approach 2:
The resilient element acts as an intermediary between the float lever mechanism and the orifice closing elements. It mediates the force transmission, allowing quick float movement for rapid response while softening the impact on mechanical components. The spring provides a compliant interface that reduces direct hard contact and wear during operational cycles.
4Loss of time
If air venting capability is enhanced during startup, then the production time and corrosion are reduced, but the device complexity increases
Solution Approach 1:
The existing orifices and float lever mechanism serve dual functions - condensate discharge and air venting. During startup, when air is present in the steam system, the float remains in a position that opens both the first and second orifices, allowing rapid air evacuation. The same mechanical components used for condensate control automatically provide air venting capability, eliminating the need for separate air vent mechanisms and maintaining device simplicity.
Solution Approach 2:
The steam trap automatically performs air venting during startup without requiring additional controls or mechanisms. The float position naturally opens the orifices to vent air, and as condensate accumulates and the float rises, the system self-regulates to close orifices for condensate discharge. This self-service approach handles both air venting and condensate discharge through the same components, avoiding increased device complexity.
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 double orifice design significantly improves condensate discharge rates and reduces wear and tear, enabling efficient handling of high and variable condensate loads, and effective air venting, resulting in a more compact, cost-effective, and efficient steam trap.
Implementation Method 1
a float fitted to said lever and link arrangement adapted to be displaced in said enclosed space, in response to a level of condensate resident in said space
Implementation Method 2
a resilient element is provided between said lever and link arrangement and said second element to damp the uncovering and shutting of said second orifice
Data Source
Figure 1
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AI summary
A stream trap for discharge of condensate is disclosed. The steam trap includes a chamber (28), a first orifice (35) and at least one other orifice (40). Each of the orifices (35, 40) has closing elements (30, 32). The closing elements (30, 32) of all orifices (35, 40) are connected to an interlinked lever arrangement (18, 36) by a float (16). The orifices open in response to level of condensate in the chamber of the trap.