Non-Condensable Gas Detection in Steam Systems
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Solution Overview
Problem
Current methods for determining non-condensable gas in steam flows are either time-consuming and inaccurate or require expensive equipment, making them inefficient for industrial applications like sterilization, where precise and rapid assessment is crucial.
Innovation Solution
A method and apparatus using a fluid displacement volume with a level sensor and flow meter to monitor the liquid level and flow rate, coupled with a pressure maintaining valve and gas outlet, allowing for accurate determination of non-condensable gas by controlling the discharge and refill configurations, and calculating the gas volume based on the liquid flow and level changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional manual methods are used to determine non-condensable gas, then the measurement can be performed with simple equipment, but the process is time-consuming and inaccurate
Solution Approach 1:
The patent replaces manual mechanical measurement methods with an automated optical sensing system. A sensor detects the liquid level in the displacement chamber, and a controller automatically calculates the non-condensable gas volume based on the liquid flow rate and level changes, eliminating the need for manual reading and calculation while improving both speed and accuracy.
Solution Approach 2:
The system performs self-measurement and self-calculation automatically. The sensor continuously monitors the liquid level, the flow meter measures liquid flow rate, and the controller autonomously computes the gas volume without requiring manual intervention, thereby reducing time consumption while maintaining high measurement precision.
2Productivity
If automatic monitoring methods using sensors are used, then measurement speed is improved, but equipment cost increases significantly
Solution Approach 1:
The patent introduces a fluid displacement chamber as an intermediary mechanism between the steam condensation process and the measurement system. This chamber allows the non-condensable gas to be trapped and measured indirectly through liquid level changes, enabling the use of simpler, less expensive sensors to detect the gas volume without requiring complex direct gas sensing equipment.
Solution Approach 2:
The system replaces expensive direct gas sensors with a combination of simple liquid level sensors and flow meters. By measuring the liquid flow rate and liquid level changes in the displacement chamber, the system calculates the gas volume through mathematical relationships, achieving fast measurement speeds with significantly reduced equipment cost.
3Measurement precision
If gas sensors with high sensitivity are used to detect small quantities of non-condensable gas, then measurement accuracy is improved, but equipment cost increases
Solution Approach 1:
The fluid displacement chamber serves as an intermediary that concentrates and traps the non-condensable gas, allowing it to be measured indirectly through liquid level changes. This approach enables the use of simple, low-cost liquid level sensors instead of expensive high-sensitivity gas sensors, while maintaining accurate measurement of small gas quantities through the displacement method.
Solution Approach 2:
The patent substitutes expensive high-sensitivity gas sensors with a mechanical displacement measurement system. By measuring the volume of liquid that displaces the gas in the chamber and using flow rate data, the system calculates gas volume through mathematical computation, achieving high measurement precision for small gas quantities without requiring costly sensitive sensors.
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 efficient and cost-effective monitoring of non-condensable gas in steam flows, providing precise measurements that can detect excess gas levels, thus improving the reliability of sterilization processes without the need for expensive sensors.
Implementation Method 1
a condenser (12) having an inlet (13) for receiving a fluid flow such as a steam sample from a steam system, and a delivery line (14) for discharging a condensed fluid flow
Implementation Method 2
a level sensor (32) comprising a float (34) configured to float on a free-surface of condensate (i.e. the surface between liquid condensate and non-condensable gas) within the second fluid displacement chamber (17)
Data Source
Figure 1
Figure 2
AI summary
There is disclosed an apparatus 10 and method for determining an amount of non-condensable gas within a fluid flow containing both non-condensable gas and condensate liquid. The method comprises receiving the fluid flow in a fluid displacement volume 18 causing the non-condensable gas to rise within the volume 10; monitoring the liquid level of a free surface in the fluid displacement volume 18 to generate a level signal; monitoring the flow of liquid out of the fluid displacement volume 18 to generate a liquid flow signal; and determining the amount of non-condensable gas based on the level signal and the liquid flow signal.