Leak Detection in Thermodynamic Cycles via Sub-cooling Analysis
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Solution Overview
Problem
In thermodynamic cycle devices like ORC systems without a feed tank, conventional level sensors cannot accurately determine the filling quantity, making it difficult to detect leaks, especially during operation, and failing to comply with regulations such as (EC) No. 842/2006 regarding fluorinated greenhouse gases.
Innovation Solution
A method that determines sub-cooling in the condenser by calculating the difference between the condensation temperature and the temperature of the fluid exiting the condenser, allowing for leak detection by monitoring changes in sub-cooling and filling quantity, which can be calculated using relationships between sub-cooling and filling quantity, without the need for conventional level sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional level sensors are used to determine filling quantity, then measurement precision is improved, but device complexity increases and cost increases
Solution Approach 1:
The system uses its own operational parameters (condensation temperature, fluid exit temperature, pressure) to determine filling quantity through sub-cooling calculations, eliminating the need for external level sensors. The thermodynamic cycle device monitors its own state to self-diagnose filling levels.
Solution Approach 2:
The invention changes the measurement approach from direct level sensing to indirect parameter measurement. By measuring temperature and pressure parameters and calculating sub-cooling, the system derives filling quantity information without physical level sensors.
2Reliability
If conventional leak detection methods are used at standstill, then detection capability is achieved, but ease of operation deteriorates and productivity decreases
Solution Approach 1:
The system continuously monitors sub-cooling parameters during normal operation to detect leaks, eliminating the need to stop the system for inspection. Leak detection becomes a continuous process integrated into normal operation rather than a separate shutdown procedure.
Solution Approach 2:
The invention replaces mechanical/physical search methods (refrigerant detectors, leak detection spray) with a thermodynamic parameter-based detection system that uses temperature and pressure measurements to identify leaks through sub-cooling analysis.
3Device complexity
If the system operates without a feed tank, then device complexity is reduced, but measurement precision of filling quantity deteriorates
Solution Approach 1:
The invention measures filling quantity indirectly through thermodynamic parameters (sub-cooling temperature difference) rather than direct level measurement. This allows accurate filling determination in a tankless system by monitoring the temperature difference between condensation and fluid exit temperatures.
Solution Approach 2:
The sub-cooling temperature difference acts as an intermediary parameter that links the presence/quantity of working medium to measurable temperature and pressure values. This intermediary enables filling quantity determination without direct level sensing in the absence of a feed tank.
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
Enables accurate leak detection during operation, complies with regulatory requirements, and reduces the need for additional sensors, allowing for predictive maintenance to prevent system failure and minimize service intervals.
Implementation Method 1
a condenser for condensing vaporous working medium
Implementation Method 2
the fluid working medium is sub-cooled, i.e. is cooled to a temperature which is below the condensation temperature
Data Source
AI summary
The invention relates to a method for detecting a leak in a thermodynamic cycle device with a condenser for condensing vaporous working medium, comprising the following steps: determining sub-cooling of the working medium in the condenser, wherein sub-cooling is determined as a difference between a condensation temperature in the condenser and a temperature of a liquid working medium exiting the condenser; detecting a leak in the event that the sub-cooling determined differs from a setpoint value for the sub-cooling or in the event that a filling quantity of the working medium in the thermodynamic cycle device, being determined from the determined sub-cooling, differs from a setpoint value for the filling quantity. The invention further relates to a corresponding computer program product and to a corresponding device.