DESC:FIELD
The present disclosure relates to drain-valves.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Most industries in colder countries, use steam tracing solutions to maintain the temperature of a process fluid, and to prevent it from dropping to low temperature and freezing. The condensate generated during this process is recovered with the help of steam valves and is taken back to a condensate header. However, when the process is shut down, generally due to the lack of inlet 1 pressure, the condensate generated remains in the pipeline and manifolds. Freezing of this remaining condensate in the process line or steam valves during process shut off could result in damage to the process lines and process as it becomes impossible for steam to enter through the frozen condensate in the process line once the process starts.
To alleviate such damage, conventionally, a drain-valve is installed at the downstream of a steam valve or a manifold that evacuates condensate from the tracing line. The anti-freeze drain-valve is a mechanically actuated normally-open valve that discharge only cold condensate. The valve stays shut when the process is active and when the condensate temperature is above a set point, and opens only when the process is turned off and when the condensate temperature starts to drop. This response of the valve helps in draining left over condensate in the line and prevents the condensate in the line from freezing. Thus, the valve ensures that the condensate does not get clogged in the process line or in the manifold during process-off condition. A temperature sensitive actuator is provided in the valve for opening and closing the valve. The temperature sensitive mechanism drains the left-over condensate, below a set temperature, from the process line during process-off condition and prevents the condensate from freezing in the line. However, the conventional valve is not capable of draining condensate at very low temperatures and handling high pressure and high temperature process operating conditions as well. As a result, during the process, high pressure and high temperature condensate reaching the drain leg from the valve can damage the actuator and the valve mechanism, and reduce the process efficiency.
Only a single thermostatic actuator wax actuator is present in the existing valve. For the thermostatic actuator wax actuator, the maximum operating temperature is 150ºC. Due to these constraints, the previous model can only tolerate temperatures up to 150ºC; any temperature over that may cause damage to the actuator. As a result, the existing valve cannot be used in applications where the temperature is higher than 150ºC.
Therefore, there is felt a need for a drain-valve that alleviates the aforementioned drawbacks.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present disclosure is to provide a drain-valve.
Another object of the present disclosure is to provide a valve which can efficiently discharge condensate of any temperature less than a set temperature at all operating conditions.
Still another object of the present disclosure is to provide a valve which is capable of enabling quick discharge of condensate load remaining in the valve upstream during process off condition.
Another object of the present disclosure is to provide a valve which is capable of preventing freezing of condensate in the process pipelines.
Yet another object of the present disclosure is to provide a valve which can reduce the start-up time and effectively reduce any possibility of process damage.
One object of the present disclosure is to provide a valve which ensures that the process remains unaffected even during valve failure.
Another object of the present disclosure is to provide a valve which can discharge condensate of temperature relatively closer to its freezing point, thereby improving the condensate recovery factor.
Yet another object of the present disclosure is to provide a valve which can also operate at higher temperature and pressure conditions.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure discloses a drain-valve, the valve configured to be mounted downstream of a steam manifold within a process line to collect residual condensate and further configured to discharge the residual condensate before freezing, the valve comprising a housing having an inlet and an outlet. A primary valve body is positioned downstream of the inlet, the primary valve body configured with a primary thermostatic actuator to regulate the flow of the residual condensate at a first predefined temperature before freezing. A secondary valve body is mounted downstream of the primary valve body. The secondary valve body is configured with a secondary thermostatic actuator to regulate the flow of the residual condensate through the secondary valve body at a second temperature and further configured to discharge the residual condensate through the outlet. A plurality of sensing means is configured within the primary valve body and the secondary valve body, each of the sensing means configured to monitor temperature and pressure of the residual condensate to generate corresponding sensed temperature and sensed pressure respectively.
In a preferred embodiment, the plurality of sensing means includes a first pressure sensing unit and a first temperature sensing unit configured within the primary valve body, and a second pressure sensing unit and a second temperature sensing unit configured within the secondary valve body, the actuators includes a first actuator and a second actuator, configured within the primary valve body and the secondary valve body respectively.
In a preferred embodiment, the first pressure sensing unit and the first temperature sensing unit are configured to sense the pressure and temperature of the residual condensate received via the inlet in to the primary valve body.
In a preferred embodiment, the first temperature sensing unit is configured to activate the first actuator if the sensed temperature is below 75°C to facilitate the flow of the residual condensate through the primary valve body.
In a preferred embodiment, the second pressure sensing unit and the second temperature sensing unit are configured to sense the pressure and temperature of the residual condensate received via the primary valve body in to the secondary valve body.
In a preferred embodiment, the second temperature sensing unit is configured to activate the second actuator if the sensed temperature is below 6°C to enable the discharge of the residual condensate through the outlet of the housing before freezing.
In a preferred embodiment, the first temperature sensing unit and the second temperature sensing unit are typically a bimetallic temperature actuator.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
A drain-valve, of the present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1 shows a sectional view of the existing drain-valve, in accordance with a preferred embodiment of the prior art;
Figure 2 shows an isometric view of the drain-valve showing the inlet 1 and the outlet 2 configured thereon, in accordance with a preferred embodiment of the present disclosure;
Figure 3 shows a sectional view of the drain-valve of Figure 2;
Figure 4 shows a sectional view of the drain-valve of Figure 2 with both the primary valve and the secondary body occupying their respective seats in a close condition;
Figure 5 shows a sectional view of the drain-valve of Figure 2 with the primary valve raised off its seat in open condition and the secondary valve body 13 in close condition;
Figure 6 shows a sectional view of the drain-valve of Figure 2 with both the primary valve and the secondary valve body 13 raised off their respective seats in an open condition; and
Figure 7 shows an isometric view of a manifold system attached with the drain-valve of the present disclosure.
LIST OF REFERENCE NUMERALS
1a –Anti-Freeze Drain-valve
1 – Anti-Freeze Drain-valve Inlet
2 – Anti-Freeze Drain-valve Outlet
3 – Anti-Freeze Drain-valve Base
4 – Primary valve actuator stopper
5 – Primary valve actuator
6 – Primary valve seat
7 – Secondary valve body actuator guide
8 – Secondary valve body actuator
9 – Secondary valve body head
10 – Secondary valve body seat
11 – Anti-Freeze Drain-valve Body
12 – Primary Valve
13 – Secondary valve body
14 – Spring
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms “a”, “an” and “the” may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms “comprises”, “comprising”, “including”, “includes” and “having” are open-ended transitional phrases and therefore specify the presence of stated features, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, elements, components, and/or groups thereof.
Referring to figure 1, an existing drain-valve 1a’ is shown. The existing anti-freeze drain-valve 1a’ is deficient of a mechanism to discharge low temperature low pressure condensate accumulated in a manifold 15’, and to handle extreme process operating conditions, by staying shut. The existing drain-valve 1a’ includes only a single valve assembly including a valve seat 6’ which obstructs a valve actuator 5’.

The existing drain-valve 1a’ lacks a mechanism that remains intact when exposed to high-temperature and high-pressure conditions. existing anti-freeze drain trap is not capable of discharging high condensate loads with minimal differential pressure across the valve. existing anti-freeze drain-valve doesn’t have a feature to protect temperature sensitive valve mechanism from high pressure and high temperature condensate.

The existing drain-valve 1a’ doesn't have a mechanism to discharge low-temperature low-pressure condensate and to handle extreme process operating conditions, by staying shut. Moreover, the existing drain-valve 1a’ lacks a mechanism that remains intact when exposed to high-temperature and high-pressure conditions. Still further the existing drain-valve 1a’ is not capable of discharging high condensate loads with minimal differential pressure across the valve. Additionally, the existing drain-valve 1a’ doesn’t have a feature to protect the thermostatic actuator valve mechanism from high pressure and high-temperature condensate. The existing valve 1a’ maximum temperature was 150ºC, and it could not be used in applications where the operating temperature was higher than 150ºC.

Referring to the figures 2-4, a valve 1a is shown in accordance with an embodiment of the present disclosure. The valve 1a is configured to be mounted downstream of a steam valve or a manifold 15 to receive/collect accumulated or residual condensate within a process line or a pipeline and further configured to discharge the accumulated condensate prior to freezing to environment, the valve 1a comprising a housing 3, a primary valve body 12 hereinafter referred to as primary valve 12, a secondary valve body 13 (hereinafter referred to as secondary valve 13), and a sensing means (not shown in figures).

The housing 3 has an inlet 1 configured to receive the accumulated condensate therein. An outlet 2 is configured on the housing 3 located downstream to the inlet 1 to discharge the accumulated condensate prior to freezing.

The primary valve 12 is configured to be positioned downstream of the inlet 1 within the housing 3. The primary valve 12 is configured with a first temperature-sensitive actuator 5 to sense the temperature of the condensate entering through the inlet 1. The primary valve 12 is further configured to allow the flow of condensate if the sensed temperature of the condensate is within a first predefined temperature limit T1.

The secondary valve body 13 is mounted downstream of the primary valve 12 within the housing 3. The secondary valve body 13 is configured with a second temperature-sensitive actuator 8 to sense the temperature of the condensate entering the secondary valve body 13. The secondary valve body 13 is configured to receive the condensate at the first predefined temperature limit T1. The secondary valve body 13 is further configured to sense the temperature of the condensate to allow the discharge of condensate through the outlet 2 if the condensate temperature is within a second predefined temperature limit T2.

The plurality of sensing means configured within the primary valve body 12 and the secondary valve body 13 body, each of the sensing means configured to monitor temperature and pressure of the residual condensate to generate corresponding sensed temperature and sensed pressure respectively. The plurality of sensing means includes a first pressure sensing unit and a first temperature sensing unit configured within the primary valve body 12, and a second pressure sensing unit and a second temperature sensing unit configured within the secondary valve body 13. The actuators include a first actuator and a second actuator configured within the primary valve body 12 and the secondary valve body 13 body respectively.
The first pressure sensing unit and the first temperature sensing unit are configured to sense the pressure and temperature of the residual condensate received via the inlet 1 in to the primary valve body 12. The first temperature sensing unit is configured to activate the first actuator if the sensed temperature is below 75°C to facilitate the flow of the residual condensate through the primary valve body 12.
The second pressure sensing unit and the second temperature sensing unit are configured to sense the pressure and temperature of the residual condensate received via the primary valve body 12 in to the secondary valve body 13 body. The second temperature sensing unit is configured to activate the second actuator if the sensed temperature is below 6°C to enable the discharge of the residual condensate through the outlet 2 of the housing 3 before freezing.
In a preferred embodiment, the first temperature sensitive actuator 5 and the second temperature sensitive actuator 8 are made of a bimetal temperature sensitive material.
In a preferred embodiment, the first temperature sensitive actuator 5 and the second temperature sensitive actuator 8 are normally open.
In a preferred embodiment, the first predefined temperature limit T1 is above a tolerable limit of the second valve assembly 12, and the second predefined temperature limit T2 is a temperature near the freezing point of the condensate.
Figure 1 and 2 shows an isometric view and sectional view of the anti-freeze valve 1a.
The drain-valve herein after referred to as ‘the valve’ has a cascade-valve configuration with the primary valve 12 and a secondary valve 13. Both primary 12 and secondary valve 13 include a temperature sensitive actuator. The primary valve 12 is configured to prevent high temperature condensate from coming in contact with the temperature sensitive secondary actuator, thereby protecting the actuator from high pressure and high temperature process operating conditions. More specifically, the primary valve 12 first comes in contact with an incoming condensate. The primary valve 12 is configured to open if the condensate temperature and pressure are not at their extreme values, and are further within the operating range of the secondary valve body 13. The condensate is allowed to pass through the primary valve 12, and then come in contact with the secondary valve body 13. The secondary valve body 13 prevents freezing of condensate in the pipelines by discharging condensate when the condensate temperature approaches zero. If the condensate temperature is high and above secondary valve body 13 operating conditions, the primary valve 12 closes and prevents the high temperature condensate from coming in contact with the secondary valve body 13 and damaging the actuator.
In a preferred embodiment as shown in the figures 3-6, the primary valve actuator is a primary thermostatic actuator 5. The secondary valve body 13 actuator is a secondary thermostatic actuator 8.
In an embodiment, the primary valve 12 includes a first temperature sensitive bimetal actuator 5 and a seat 6.
In another embodiment, the secondary valve body 13 includes a second temperature sensitive actuator 8, a valve head 9, a valve seat 10, and a spring 14
In an embodiment, the primary valve 12 is a normally open valve.
In an embodiment, the secondary valve body 13 is a normally open valve.
The condensate coming into the valve, first comes in contact with the primary actuator 5. The actuator 5 is configured to stay open if the temperature is less than the set point. The condensate then comes in contact with the secondary valve body 13 and the actuator 8.
The secondary actuator 8 is configured to sense the condensate temperature, and is further configured to stay open if the sensed condensate temperature is close to the freezing temperature, for discharging the condensate. This ensures that the condensate doesn’t freeze inside the process and condensate lines and damage the process. Further, the condensate recovery factor is improved.
The secondary actuator 8 is also configured to close the secondary valve body 13 13 when the sensed temperature of condensate is more than the set point. As the process continues, the condensate will reach extreme temperatures, which could damage the secondary actuator 8. Therefore, as the condensate temperature goes above the safe continuous operating temperature of secondary valve body 13, the primary actuator 5 actuates and closes the primary valve 12 to isolate the secondary valve body 13. The primary actuator 5 will continue to be exposed to high temperature condensate from the process till the process is shut down. However, the secondary actuator 8 will open the valve 13 as the temperature drops below freezing temperature because it is isolated from the condensate coming in. This response of the valve 1a helps in avoiding process damage due to condensate freezing in the process line as well as the product and improving condensate recovery factor by draining condensate only of temperature close to its freezing point.
The valve 1a is configured to remove left-over condensate efficiently and prevent freezing of condensate in the process lines. The valve 1a is configured with a preset factory setting, below which the valve opens and drains condensate on the upstream. The valve 1a is configured to be normally open in case of valve failure as well, to ensure that the process is not damaged during process shut off.
Further, the valve 1a has a compact configuration that helps discharge relatively higher condensate loads in lesser time, reduces process start up duration, and withstands extreme process operating conditions. The valve 1a ensures that the condensate is drained only when the condensate temperature is closer to freezing temperatures, and thus helps improve the condensate recovery.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENT
The present disclosure described hereinabove has several technical advantages including, but not limited to, the realization of a valve:
o which can efficiently discharge condensate of any temperature less than a set temperature at all operating conditions;
o which is capable of enabling quick discharge of condensate load remaining in the valve upstream during process off condition;
o which is capable of preventing freezing of condensate in the process pipelines
o which can reduce the start-up time and effectively reduce any possibility of process damage;
o which has a normally open configuration in case of mechanism failure that ensures that the process remains unaffected even during failure
o which remains unaffected even when exposed to high temperature and high pressure conditions;
o which is capable of discharging high condensate loads with minimal differential pressure across the valve;
o which can protect temperature sensitive valve mechanisms from high pressure and high temperature condensate;
o which is capable of draining the condensate at low temperatures and remaining shut when high temperature condensate comes in;
o which can discharge condensate of temperature that is close only to freezing point of the fluid, thus improving condensate recovery factor; and
o which has a cascade-valve configuration wherein a primary mechanism isolates a temperature-sensitive secondary mechanism from high pressure high temperature condensate coming in contact with it.
The foregoing disclosure has been described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Any discussion of materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. ,CLAIMS:WE CLAIM:
1. A drain-valve (1a), said valve (1a) configured to be mounted downstream of a steam manifold (15) within a process line to collect residual condensate and further configured to discharge said residual condensate before freezing, said valve comprising:
• a housing (3) having an inlet (1) and an outlet (2);
• a primary valve body (12) positioned downstream of said inlet (1), said primary valve body (12) configured with a primary thermostatic actuator (5) to regulate the flow of said residual condensate at a first predefined temperature (T1) before freezing;
• a secondary valve body (13) body mounted downstream of said primary valve body (12), said secondary valve body (13) body configured with a secondary thermostatic actuator (8) to regulate the flow of said residual condensate through said secondary valve body (13) body at a second predefined temperature (T2) and further configured to discharge said residual condensate through said outlet (2); and
• a plurality of sensing means configured within said primary valve body (12) and said secondary valve body (13), each of said sensing means configured to monitor temperature and pressure of said residual condensate to generate corresponding sensed temperature and sensed pressure respectively.
2. The valve as claimed in claim 1, wherein said plurality of sensing means includes a first pressure sensing unit and a first temperature sensing unit configured within said primary valve body (12), and a second pressure sensing unit and a second temperature sensing unit configured within said secondary valve body (13) body, said actuators includes a first actuator and a second actuator, configured within said primary valve body (12) and said secondary valve body (13) body respectively.
3. The valve as claimed in claim 2, wherein said first pressure sensing unit and said first temperature sensing unit are configured to sense the pressure and temperature of the said residual condensate received via said inlet (1) into said primary valve body (12).
4. The valve as claimed in claim 3, wherein said first temperature sensing unit is configured to activate said first actuator if the sensed temperature is below 75°C to facilitate the flow of said residual condensate through said primary valve body (12).
5. The valve as claimed in claim 2, wherein said second pressure sensing unit and said second temperature sensing unit are configured to sense the pressure and temperature of the said residual condensate received via said primary valve body (12) into said secondary valve body (13) body.
6. The valve as claimed in claim 5, wherein said second temperature sensing unit is configured to activate said second actuator if the sensed temperature is below 6°C to enable the discharge of said residual condensate through said outlet (2) of said housing (3) before freezing.
7. The valve as claimed in claim 1, wherein said first temperature sensing unit and said second temperature sensing unit are typically a bimetallic temperature actuator.
Dated this 13th day of March, 2024

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
of R. K.D EWAN & CO.
Authorized Agent of Applicant

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT MUMBAI