Steam Trap Diversion Valve for Condensate Quality Separation
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Solution Overview
Problem
Conventional steam trap systems fail to segregate impure condensate, leading to contamination of condensate recovery systems, resulting in significant water and heating cost losses, and lack the ability to detect failures and take corrective action.
Innovation Solution
A steam trap system with a diversion valve and sensing units to separate condensate based on conductivity and temperature, allowing impure condensate diversion through a bypass outlet and pure condensate through a trap mechanism, with remote monitoring and communication capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional steam trap systems remove all condensate indiscriminately, then condensate is removed from the steam space, but impure condensate contaminates the condensate recovery system and causes loss of water and heating energy
Solution Approach 1:
The steam trap system segments the condensate discharge path into two separate channels: a bypass line for impure condensate and a trap mechanism for pure condensate. This segmentation allows selective routing of condensate based on quality, preventing contamination of the recovery system while preserving usable condensate for return
Solution Approach 2:
The patent introduces an intermediary detection mechanism (sensing unit) that analyzes condensate quality parameters such as conductivity and temperature. This intermediary device mediates between the steam space and condensate recovery system by identifying impure condensate and diverting it through the bypass before it can contaminate the recovery system
2Reliability
If conventional steam trap systems lack detection mechanisms, then the system structure remains simple, but failures in closed condition cannot be detected or corrected
Solution Approach 1:
The patent implements feedback through sensing units that continuously monitor condensate quality and system operation status. The sensed information is fed back to a control mechanism that can detect failures in closed condition and trigger appropriate responses, such as switching to bypass mode or generating alarm signals
Solution Approach 2:
The steam trap system performs self-diagnosis and self-correction through integrated sensing and control mechanisms. When a failure is detected (such as the trap mechanism failing to open), the system automatically activates the bypass as a backup, enabling self-service operation without external intervention
3Reliability
If steam trap systems drain large quantities of hot impure condensate, then the condensate recovery system is protected from contamination, but significant water collection cost, water treatment cost, and heating cost are lost
Solution Approach 1:
The patent applies local quality by treating different portions of condensate differently based on their specific characteristics. Impure condensate is diverted through the bypass while pure condensate is routed through the trap mechanism for recovery. This localized treatment approach ensures that only contaminated condensate is discarded, minimizing energy and water loss
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
Efficient separation of pure condensate, remote monitoring, and failure detection, reducing water and heating costs while preventing system contamination and waterlogging, and enhancing process efficiency.
Implementation Method 1
at least one first sensing unit, configured within the inlet port and is further configured to generate at least one first sensed value corresponding to the steam flow characteristics
Implementation Method 2
the steam flow characteristics include conductivity and the temperature of the condensate fluid of the steam
Implementation Method 3
Steam traps are broadly classified on the basis of their generic operations i.e. 'continuous flow' and 'intermittent flow'. Continuous flow type traps are typically configured with float traps that removes the condensate which is in liquid phase and holds back the steam which is in vapour phase
Data Source
AI summary
The present disclosure relates to a steam trap system, including: an inlet port to receive steam; a diversion valve, configured to be mounted on the inlet port and is further configured to be branched to a first passage and a second passage; a bypass outlet, configured to be in communication with the first passage; a trap mechanism, configured to be in communication with the second passage; at least one first sensing unit, configured to generate at least one first sensed signal corresponding to the steam flow characteristics; a control unit, configured to be connection with the first sensing unit to generate an actuating signal; and a valve actuator, configured to be in communication with the control unit to selectively activate either the bypass outlet port or the trap mechanism, to allow separation of the condensate from the steam. Advantageously, the system efficiently removes the condensate from the steam.