Electronic Steam Trap With Saturation-Based Condensate Control
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Solution Overview
Problem
Existing steam trap systems face challenges in efficiently managing condensate removal in steam systems, leading to potential damage and inefficiencies due to the inability to accurately control condensate discharge and prevent steam loss.
Innovation Solution
An electronic self-contained steam trap system that measures temperature and pressure internally, using a thermoelectric generator for power and an electro-mechanically actuated valve to control condensate discharge based on sub-cooling temperature, allowing for both cycling and continuous regulation modes to optimize condensate removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If mechanical steam traps or traditional electronic drain systems are used, then condensate can be removed from steam lines, but steam loss occurs due to inaccurate temperature sensing and premature valve opening
Solution Approach 1:
The patent introduces a thermally conductive coupling member as an intermediary that transfers heat from the steam line to the temperature sensor. This mediator ensures accurate temperature measurement by establishing reliable thermal contact between the sensor and the steam line, preventing premature valve opening due to inaccurate readings and thereby reducing steam loss
Solution Approach 2:
The patent replaces mechanical temperature sensing mechanisms with an electronic temperature sensor that is thermally coupled to the steam line. This substitution enables more precise temperature measurement and integration with electronic control systems, allowing for accurate determination of condensate presence and preventing steam loss through premature discharge
2Reliability
If remote pressure measurement and calculated saturation temperature are used, then steam trap operation can be controlled, but response time is delayed and accuracy is reduced
Solution Approach 1:
The patent segments the measurement functions by placing both pressure and temperature sensors directly at the steam trap location. This segmentation allows independent, localized measurement of actual conditions, enabling immediate response to condensate formation without waiting for remote data transmission and calculation, thereby reducing response time while maintaining reliable control
Solution Approach 2:
The patent implements preliminary local measurement of pressure and temperature conditions at the steam trap. By having sensors already in place and continuously monitoring conditions, the system is prepared to detect condensate formation immediately and respond without delay, eliminating the time required for remote measurement and data processing
3Productivity
If continuous monitoring and regulation are implemented, then condensate removal is optimized, but system complexity and power requirements increase
Solution Approach 1:
The patent implements a self-contained control system where the electronic controller continuously monitors local temperature and pressure conditions and automatically actuates the valve based on predetermined logic. The system serves itself by making autonomous decisions about when to open or close the valve, eliminating the need for external monitoring equipment or complex centralized control systems, thereby maintaining high productivity with reduced complexity
Solution Approach 2:
The patent combines the temperature sensor, pressure sensor, electronic controller, and valve actuation mechanism into an integrated steam trap assembly. This merging of functions into a single unit simplifies the overall system architecture while enabling continuous monitoring and regulation, achieving high condensate removal efficiency without proportionally increasing system complexity
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 system effectively regulates condensate discharge, minimizing steam loss and maintaining efficient operation by automatically controlling the condensate valve based on calculated saturation temperatures, ensuring reliable condensate removal and system performance.
Implementation Method 1
A thermoelectric generator (TEG) power source is disposed in thermal contact with the steam trap and configured to generate electrical power from heat energy of steam/condensate passing into inlet port
Implementation Method 2
Pressure and temperature sensors are disposed to monitor pressure and temperature conditions in the internal passageway
Implementation Method 3
Temperature and pressure sensors are disposed to monitor pressure and temperature conditions in the internal passageway
Implementation Method 4
An electro-mechanically actuated condensate discharge valve is disposed upstream of the outlet port and vents condensate from the steam trap when actuated to an open position
Data Source
AI summary
A self-contained electronic steam trap drains condensate from a steam system. The steam trap includes a drain pipe adapted for fluid communication with a steam supply system. Pressure and temperature sensors measure pressure and temperature in an internal passageway of the steam trap. A condensate discharge valve is disposed at or upstream of an output port of the drain pipe. The condensate discharge valve is controlled based on the measured pressure and temperature and a calculated steam saturation temperature. Both a cycling mode and a regulation mode of automatic valve operation are described.