Float-Operated Condensate Pumping Trap for Low-Pressure Discharge
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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 and reduced heat transfer rates, especially at low installation heights and during stalling conditions, where upstream pressure drops below downstream pressure.
Innovation Solution
A pumping and trapping device comprising a vessel, float, float lever, connecting link, bell crank lever, biasing member, actuator link, and trap valve, with a knuckled pivot mechanism that allows angular displacement of the float lever and compression of the biasing member, preventing tensile load induction and optimizing condensate discharge without affecting process efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional pressure powered pumps are used to pump condensate, then condensate can be removed from heat exchangers, but the pumps cannot operate at small filling heads and require more accommodation space
Solution Approach 1:
The patent uses a flexible diaphragm instead of rigid pump components. The diaphragm flexes to create pumping action, eliminating the need for complex rigid mechanisms and reducing overall device volume while maintaining condensate discharge capability.
Solution Approach 2:
The invention extracts the essential pumping function from complex mechanical assemblies and implements it through a simplified diaphragm-based mechanism, removing unnecessary components and reducing accommodation space requirements.
2Ease of operation
If conventional pumps with rigid float and lever connections are used, then pumping action is achieved, but tensile load is induced in the spring which lowers the pressures up to which the device can remain operable
Solution Approach 1:
Instead of using a rigid connection that induces tensile load on the spring, the patent inverts the approach by using a flexible diaphragm that converts the spring's compressive force directly into pumping action, eliminating tensile loads on the biasing spring.
Solution Approach 2:
The patent replaces the rigid mechanical float-lever connection with a flexible diaphragm mechanism, substituting rigid mechanical transmission with flexible membrane-based actuation that avoids inducing tensile loads.
3Ease of manufacture
If conventional pumps are used at low installation heights, then installation is simplified, but condensate re-enters the heat exchanger causing reduced heat transfer rate
Solution Approach 1:
The device uses the available head (even when very small) and the pressure differential across the diaphragm to automatically generate pumping action, making the system self-actuating and effective at low installation heights without compromising heat transfer.
Solution Approach 2:
The patent changes the operating parameters by utilizing the pressure differential across the diaphragm and the small available head to create effective pumping action, enabling operation at low installation heights while preventing condensate re-entry.
4Productivity
If snap action mechanism with extension spring is used, then pumping fluid is achieved, but more accommodation space is required
Solution Approach 1:
The patent replaces the snap action mechanism with a flexible diaphragm that provides continuous pumping action, eliminating the need for complex snap action components and reducing the overall volume of the device while maintaining fluid pumping capability.
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 from heat exchangers across varying pressure conditions, maintains process efficiency, and increases per stroke discharge by 22% while being compact and easy to maintain, eliminating tensile load on the biasing member during trapping.
Implementation Method 1
The float lever is pivotally connected to the support bracket and the extension. The extension is configured to be angularly displaced about the pivotal connection between the float lever and the extension at a predetermined angle.
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.
Data Source
AI summary
A pumping and trapping device is provided. The pumping and trapping device removes condensate from a heat exchanger even when upstream pressure in the device is lesser than the downstream pressure. The device includes a float operated mechanical linkage. The float is displaceable with respect to condensate level within a vessel of the device. The mechanical linkage is configured to selectively operate a steam inlet port and a steam outlet port configured on the vessel, thereby removing condensate accumulated within the vessel.