Programmable Steam Trap Reduces Loss
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Solution Overview
Problem
Conventional steam trap apparatuses lack flexibility and controllability, leading to inefficiencies, steam loss, and increased maintenance costs due to their mechanical operation and inability to adapt to varying operating conditions such as pressure and load.
Innovation Solution
A Programmable Steam Trap apparatus with electronically controlled actuated valves and sensors that compare temperature and pressure readings to the steam saturation curve, allowing for real-time adjustment to prevent steam loss and efficiently remove condensate and non-condensable gases, featuring a control system that can input time delays and accommodate varying steam system pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional mechanical steam traps are used, then the apparatus is simple in structure, but it lacks flexibility and controllability leading to steam loss
Solution Approach 1:
The patent replaces the conventional mechanical steam trap operation with an electronically controlled system. Sensors detect temperature and pressure conditions, and an electronic controller actuates the valve based on these readings compared against saturation curve data, eliminating the need for mechanical float or bimetallic mechanisms and enabling programmable control strategies.
Solution Approach 2:
The system incorporates saturation curve data that defines relationships between temperature, pressure, and steam quality. The controller programmatically adjusts valve actuation timing based on real-time sensor readings compared to saturation conditions, allowing dynamic adaptation to varying operating parameters such as pressure and load conditions.
2Loss of energy
If conventional steam traps operate mechanically, then the device is simple to operate, but it causes steam loss and inefficiency
Solution Approach 1:
The system continuously monitors temperature and pressure conditions through sensors and uses this feedback to control valve actuation. The controller compares real-time sensor readings against saturation curve data and adjusts the actuated valve accordingly, creating a closed-loop control system that prevents steam loss by opening the valve only when condensate or non-condensable gases are actually present.
Solution Approach 2:
The system incorporates time delay parameters that allow anticipatory control. The controller can be programmed to open the valve before saturation conditions are fully reached, preventing condensate accumulation that would otherwise cause steam loss. This preliminary action is based on programmable time delays and saturation curve predictions.
3Productivity
If conventional steam traps are used, then maintenance costs are reduced in terms of device simplicity, but actual maintenance costs increase due to inefficiency and steam loss
Solution Approach 1:
The system performs self-diagnosis and self-adjustment through its sensor array and programmable controller. The controller continuously monitors saturation conditions and automatically adjusts valve actuation timing, eliminating the need for manual intervention or complex mechanical adjustment mechanisms. The system serves itself by comparing sensor readings against embedded saturation curve data and making real-time control decisions.
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 Programmable Steam Trap apparatus enhances efficiency, flexibility, and controllability, reducing steam loss and maintenance costs by accurately replicating the steam saturation curve, allowing for real-time data collection and optimized sterilization processes, thereby minimizing energy and water usage.
Implementation Method 1
a first temperature sensor, a second temperature sensor, a pressure sensor
Implementation Method 2
a pressure sensor positioned upstream from the actuated valve
Implementation Method 3
determines whether to open the actuated valve to release condensate, air or non-condensable gas from the steam space based on temperature reading from the temperature sensors and the pressure reading from the pressure sensor
Data Source
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AI summary
An apparatus and a method for removing condensate and unwanted gas from vapor/liquid systems while preventing steam loss are provided. The steam trap apparatus replaces the automatic valve type steam trap with an efficient, controllable, and programmable steam trap. In addition, the improved steam trap apparatus allows for real-time data collection during sterilization and other operations.