Valve Induction Heater Prevents Condensate Accumulation

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Solution Overview

Problem

Steam control valves operating under the discharging principle tend to develop condensate on internal surfaces due to temperature lag behind pressure changes, leading to performance penalties like increased opening times as condensate evaporates, requiring larger steam volumes to be discharged.

Innovation Solution

A heating modality, such as an induction heater, is integrated into the valve assembly to maintain the valve temperature above the saturation temperature of the system pressure, preventing condensate formation by keeping the metal temperature higher than the steam temperature.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If insulation is applied to the valve, then heat loss is reduced, but condensate still forms due to insulation imperfections and temperature lag

Engineering Contradiction:

Improveheat lossVSAvoidcondensate formation

Core Design Contradiction:

Loss of energyVSObject-affected harmful factors

Solution Approach 1:

The heating element applies heat to the valve body in advance and continuously, counteracting the tendency toward condensate formation before it occurs. This preliminary anti-action prevents the temperature drop that would otherwise lead to condensate, even when insulation is present.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The heating element acts as an intermediary between the external environment and the valve internals, actively maintaining thermal conditions that prevent condensate formation. It mediates the thermal balance by compensating for heat loss through insulation imperfections.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stress or pressure

If the valve is large and heavy, then it can handle high pressure, but temperature changes lag behind pressure changes causing condensate

Engineering Contradiction:

Improvepressure handling capacityVSAvoidtemperature response time

Core Design Contradiction:

Stress or pressureVSTemperature

Solution Approach 1:

The heating element performs preliminary heating of the valve body, so that when pressure changes occur, the temperature is already adjusted and ready to respond. This eliminates the lag between pressure and temperature changes that would otherwise cause condensate formation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The heating element operates continuously or in a sustained manner to maintain the valve body temperature in sync with pressure conditions. This continuous thermal action ensures that the heavy valve body's temperature follows pressure changes without dangerous lag.

Inventive Principle:

Principle #20Continuity of useful action

3Quantity of substance

If condensate accumulates in the valve, then steam volume to be discharged increases, but opening time increases as condensate must evaporate first

Engineering Contradiction:

Improvesteam volumeVSAvoidopening time

Core Design Contradiction:

Quantity of substanceVSLoss of time

Solution Approach 1:

The heating element converts the potential harm of condensate formation into a benefit by preventing condensate from forming in the first place. By maintaining the valve body above saturation temperature, the system ensures that only steam is present, eliminating the time-consuming evaporation step.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Temperature

If the valve temperature falls below saturation temperature, then condensate forms on internal surfaces, but heating the valve is required to prevent this

Engineering Contradiction:

Improvevalve temperatureVSAvoidcondensate accumulation

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The heating element enables the valve to self-regulate its thermal state, maintaining its own temperature above the saturation point. The valve essentially serves itself by having the heating element compensate for its inherent thermal mass and slow response to pressure changes.

Inventive Principle:

Principle #25Self-service

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

This solution effectively avoids condensate accumulation, optimizing the discharge path and reducing opening times by ensuring the valve operates with only steam, eliminating design uncertainties from mixed water and steam volumes.

Implementation Method 1

A heating modality, such as an induction heater, is integrated into the valve assembly to maintain the valve temperature above the saturation temperature of the system pressure

Methodology Applied

Scientific EffectInduction heating: Induction Heating

Implementation Method 2

a heating modality or device is cooperatively engaged to a prescribed location on a valve housing or body of a valve to effectively maintain the temperature of the valve

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS8783283B2Heating device for valve to prevent internal accumulation of condensate

Publication Date: 2014.07.22 IMI CRITICAL ENGINEERING LLC

AI summary

In accordance with the present invention, there is provided a valve assembly wherein a heating modality such as an induction heater is cooperatively engaged to a prescribed location on a valve housing or body of a valve to effectively maintain the temperature of the valve above the saturation temperature of the related system pressure. Maintaining this temperature differential effectively avoids the accumulation of condensate within the interior of the valve body and/or on other internal structural features thereof.