Integrated Condensing Boiler Relief Valve for Leak Detection

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing condensing boiler pressure relief valve assemblies face issues with visibility and potential leaks, leading to difficulties in diagnosing small leaks and weeping, and there is a risk of combustion products escaping when attempting to direct discharge into the condensate drainpipe.

Innovation Solution

The pressure relief valve is integrated within the condensing boiler, connected to the fluid circuit and sump, allowing discharge without external pipework and a separate tundish, with a detachable cover for easy inspection and a control system to manage condensate discharge, ensuring safe and efficient operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If the pressure relief valve outlet is connected to the condensate drainpipe through additional pipework within the boiler, then the need for external discharge piping is eliminated, but the ability to detect leaks and weeping is lost

Engineering Contradiction:

Improvepiping complexityVSAvoidleak detection

Core Design Contradiction:

Device complexityVSDifficulty of detecting and measuring

Solution Approach 1:

A transparent or translucent observation window is introduced as an intermediary element between the pressure relief valve outlet and the condensate drainpipe connection. This window allows visual inspection of the discharge point without requiring disassembly or complex detection systems, thus maintaining piping simplicity while enabling leak detection.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The observation window utilizes transparent or translucent material properties to allow visual detection of water discharge. The change from transparent (no leak) to opaque/wet (leak present) provides a simple visual indicator system without adding mechanical complexity.

Inventive Principle:

Principle #32Color changes

2Device complexity

If the pressure relief valve is moved to evacuate directly into the water vapour condensate drainpipe, then external discharge piping is eliminated, but the risk of combustion products escaping increases

Engineering Contradiction:

Improvepiping complexityVSAvoidcombustion product leakage

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The pressure relief valve discharge outlet is extracted from the internal boiler environment and positioned at a separate location that discharges to atmosphere or a safe external location. This separation ensures that even if the valve leaks or malfunctions, combustion products cannot escape into the boiler housing or condensate system, while the piping remains simplified through direct connection to the drainpipe.

Inventive Principle:

Principle #2Taking out (Extraction)

3Difficulty of detecting and measuring

If a separate tundish is added to the condensate trap external to the boiler to enable viewing of discharge, then leak detection is improved, but the risk of combustion product escape increases

Engineering Contradiction:

Improveleak detectionVSAvoidcombustion product leakage

Core Design Contradiction:

Difficulty of detecting and measuringVSObject-affected harmful factors

Solution Approach 1:

The observation function is merged into the existing condensate trap assembly rather than adding a separate tundish. The transparent observation window is integrated directly into the trap body, allowing leak detection while maintaining the seal integrity that prevents combustion product escape. This combines the detection function with the existing safety architecture.

Inventive Principle:

Principle #5Merging (Combining)

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

This solution eliminates the need for external pipework, reduces component count, and allows for quick identification of leaks or malfunctions, ensuring safe and efficient pressure relief without risking combustion product leakage.

Implementation Method 1

pressure relief valve connected to the fluid circuit and sump

Methodology Applied

Scientific EffectPressure relief: Pressure Gradient

Implementation Method 2

water vapour in the combustion gases condenses. The condensation of the water vapour on the heat exchanger enables recovery of some of the latent heat

Methodology Applied

Scientific EffectCondensation: Condensation

Implementation Method 3

one or more heat exchangers to transfer the heat generated to a fluid travelling through a fluid circuit

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentEP2941601B8Condensing boiler

Publication Date: 2019.10.09 IDEAL BOILERS

AI summary

A condensing boiler comprises combustion chamber, a heat exchanger and a fluid circuit connected to the heat exchanger. The fluid circuit comprises an inlet for fluid to be heated and an outlet for heated fluid, an exhaust flue for exhausting combustion products from the combustion chamber, and a sump for collecting condensed water vapour from combustion products. The condensing boiler further comprises a pressure relief valve operatively connected to the fluid circuit and the sump. The pressure relief valve comprises an exhaust port directly coupled to the sump.