FIELD

The present invention relates to condensate pumps and an overflow detection mechanism, more particularly a system for failure detection in a condensate pump.

BACKGROUND

The background information herein below relates to the present disclosure but is not necessarily prior art.

A condensate pump helps in pumping evacuated condensate to feed-water tank and improving the condensate recovery factor of processes in industries. The condensate pumps use steam to pump the condensate. In a typical condensate pump, there is a pump shell within which there is a mechanism to pump the condensate and a receiver in which the evacuated condensate from multiple traps is collected. The receiver outlet is connected to the pump shell. A conventional condensate pump is installed downstream of multiple processes to collect the condensate evacuated from all of the processes and pump it back to the boiler feed-water tank. A float-based mechanism is used to open and close the motive steam line which helps in pumping the condensate reaching the pump shell.

During operation, the mechanism can get damaged and stop pumping the condensate. Incorrect selection of pump or undersized pump selection could also result in flooding of the pump. An overflow line has been provided in the condensate pump to avoid any process damage and drain the condensate in the event of flooding due to the aforementioned reasons. In a closed-loop configuration, which is normally done to meet zero open discharge norms, it is difficult to identify the failure or flooding of a conventional condensate pump.

There is, therefore, felt a need for a mechanism 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 ameliorate one or more problems of the background or to at least provide a useful alternative. An object of the present disclosure is to provide a system for a failure detection mechanism in a condensate pump.

Another object of the present disclosure is to provide a system that can detect flooding failure in condensate pumps due to either mechanism failure or incorrect sizing and selection of pump.

Yet another object of the present disclosure is to provide a system that shows local indications of the failure through multi-colored LED.

An object of the present disclosure is to provide a system for a condensate pump that indicates flooding of the condensate pump and shares the status through wired or wireless communication protocols.

Another object of the present disclosure is to provide a system that alerts users through an alarm to take corrective action.

Yet another object of the present disclosure is to provide a system that prevents damage to the process equipment due to flooding failure in the condensate pump.

Another object of the present disclosure is to provide a system that saves water treatment cost and heating costs.

Yet another object of the present disclosure is to provide a system that is environmentfriendly.

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 relates to a system for failure detection in a condensate pump, the pump having a pump housing, a receiver, an overflow line, and an exhaust line; the system comprises at least one sensing device comprising an electronic unit, a sensor probe, a float, and at least two stoppers, wherein the at least one sensing device has a reed switch; the reed switch is installed in the sensor probe between the stoppers and is configured to detect and indicate the failure of the condensate pump when fluid level in the condensate pump is above a predefined level. In accordance with the embodiment of the present disclosure, the at least one sensing device is mounted on the condensate pump.

In accordance with the embodiment of the present disclosure, the electronic unit comprises an electronic housing and a display panel; the electronic unit is configured to share the working condition of the condensate pump to a control panel through a wired or wireless network; and the display panel is configured to display the working condition of the condensate pump.

In accordance with the embodiment of the present disclosure, the float is of a magnetic material.

In accordance with the embodiment of the present disclosure, the float has a hollow center.

In accordance with the embodiment of the present disclosure, the at least two stoppers are positioned as an operative upper stopper and an operative lower stopper and are configured to constrain the movement of the float.

In accordance with the embodiment of the present disclosure, the operative upper stopper is positioned in the proximity of the receiver surface and the operative lower stopper is positioned above the overflow line.

In accordance with the embodiment of the present disclosure, the reed switch is toggled in response to the movement of the float to detect failure of the condensate pump.

In accordance with the embodiment of the present disclosure, the predefined level is the operative level of the overflow line of the condensate pump.

In accordance with the embodiment of the present disclosure, the indication for the failure of the condensate pump is in the form of an alarm, and a display.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING

The present disclosure relates to a system for failure detection in a condensate pump. The present disclosure will now be described with the help of the accompanying drawing, in which:

Figure 1: illustrates a sensing device mounted on a condensate pump in accordance with the present disclosure; Figure 2: illustrates a sensing device in accordance with the present disclosure; and

Figure 3: illustrates a block diagram of a sensing device communication network in accordance with the present disclosure.

LIST OF REFERENCE NUMERALS USED IN DETAILED DESCRIPTION AND DRAWING

1000 failure detection system

100 sensing device

1 Electronic unit la electronic housing

2 Sensor mounting head

3 Float Stopper

3 a upper stopper

3b lower stopper

4 Float

5 Sensor Probe

200 Condensate Pump

6 Pump housing

7 Motive Line Steam Trap

8 Motive Steam Inlet Line

9 Condensate Recovery Meter

10 Condensate Inlet

11 Condensate receiver 12 Overflow Line

13 Receiver Vent

14 Exhaust Line

15 LED display

300 sensing device communication system

16 wireless protocol

17 mobile device

18 wired protocol

19 distributed control system

20 IOT gateway

21 local display

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 apparatus 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. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.

As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.

The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.

A condensate pump helps in pumping evacuated condensate to feed-water tank and improving the condensate recovery factor of processes in industries. The condensate pumps use steam to pump the condensate. In a typical condensate pump, there is a pump shell within which there is a mechanism to pump the condensate and a receiver in which the evacuated condensate from multiple traps is collected. The receiver outlet is connected to the pump shell. A conventional condensate pump is installed downstream of multiple processes to collect the condensate evacuated from all of the processes and pump it back to the boiler feed-water tank. A float-based mechanism is used to open and close the motive steam line which helps in pumping the condensate reaching the pump shell.

During operation, the mechanism can get damaged and stop pumping the condensate. Incorrect selection of pump or undersized pump selection could also result in flooding of the pump. An overflow line has been provided in the condensate pump to avoid any process damage and drain the condensate in the event of flooding due to the aforementioned reasons. In a closed-loop configuration, which is normally done to meet zero open discharge norms, it is difficult to identify the failure or flooding of a conventional condensate pump.

The present disclosure envisages a system (1000) for failure detection in a condensate pump (200). The present disclosure will now be described in detail with reference to Figures 1 through Figure 3. The present embodiment does not limit the scope and ambit of the present disclosure.

In an aspect, the present disclosure relates to a system (1000) for failure detection in a condensate pump (200). The condensate pump (200) has a pump housing (6), a receiver (11), an overflow line (12), and an exhaust line (14). The system (1000) for failure detection in the condensate pump (200) comprises at least one sensing device. Further, the sensing device (100) comprises an electronic unit (1), a sensor probe (5), a float (4), and at least two stoppers (3a, 3b). Furthermore, the sensing device has a reed switch and is installed in the sensor probe (5) between the stoppers (3a, 3b). The sensing device (100) along with the reed switch is configured to detect the pump (200) failure and accordingly indicate the failure status of the condensate pump over an LED display (15). The condensate pump (200) failure happens when the fluid level in the condensate pump (200) is above a predefined level.

Figure 1 shows the sensing device (100) mounted on the condensate pump (200) for failure detection, Figure 2 shows an isometric view of the sensing device (100) and Figure 3 shows the block diagram for the sensing device communication system.

The condensate pump (200) depicted in Figure 1 comprises a pump housing (6), a receiver (11), an overflow line (12), and an exhaust line (14). The pump housing (6) is configured within which there is a mechanism to pump the condensate and a receiver (11) in which the evacuated condensate from multiple traps is collected and the receiver vent (13) is connected to the pump housing. The overflow line (12) has been provided in the condensate pump (200) to avoid any process damage and drain the condensate in the event of flooding.

In an embodiment, the sensing device (100) is mounted on the condensate pump (200) for detecting a failure in the event of flooding. The sensing device (100) shown in Figure 2, has an electronics unit (1), a sensor probe (5), a float (4), and stoppers (3). The electronic unit is further configured with an electronic housing (la) and a display (15).

In an embodiment, the stoppers (3) are configured to constrain the movement of the float (4). There are at least two stoppers (3), an operative upper stopper (3a) and an operative lower stopper (3b). Further, the operative upper stopper (3a) is positioned in proximity to the receiver (11) surface of the condensate pump (200), and the operative lower stopper is positioned above the overflow line (12) of the condensate pump (200). The float (4) provided in the sensing device (100) moves up and down based on the level of water or condensate present inside the receiver (11) and the stoppers (3a, 3b) at both extreme levels constrain the movement of the float (4).

In an embodiment, the overflow line (12) of the condensate pump (200) is the operative level of the condensate pump (200) or the predefined level. When the fluid flow in the pump (200) is above the overflow line (12), the sensing device detects the failure and accordingly indicates the status over the display.

In an embodiment, the sensing device (100) is configured with a sensor probe (5), and the sensor probe (5) accommodates a reed switch. The reed switch is installed in the sensor probe

(5) in such a way that the position of the reed switch is in between the stoppers (3a, 3b), and the reed switch is kept in an open condition. When the float (4) comes close to the reed switch, the switch gets actuated and closes a circuit and when the float (4) moves away from the reed switch, the circuit opens. This toggling of the switch in an open and close position of the circuit is used to detect the failure in the condensate pump (200). The failure of the condensate pump here is related to the flooding or a critical fluid level in the pump housing

(6) and the receiver (11).

In an exemplary embodiment, the float is of a magnetic material and also it has a hollow center.

In an embodiment, the electronics unit (1) is mounted on the sensing device (100). The electronic unit (1) has an electronic housing (la) and a display (15). The electronic unit (1) mounted on the sensing device provides a constant voltage to the reed switch. The toggling of the reed switch in response to the float movement detects the status or the working condition of the condensate pump and generates a signal. The generated signals are shared with the control device using a wireless or wired protocol and simultaneously, based on the signal’s output, the results or the working condition of the condensate pump is displayed.

In an exemplary embodiment, the display (15) is located at the operative top of the electronic unit (1), and the indications are displayed with the help of a multi-colored LED display (15).

In an exemplary embodiment, the sensing device (100) has different types of sensors. The sensor could include but is not limited to a temperature sensor, a pressure sensor, a fluid level sensor, and the like. The sensors are connected to the control device for transmission of the detected signals related to the working condition of the condensate pump, such as pump failure, flooding of the pump, and pressure and temperature conditions. Further, the sensor is connected to a mobile device (17) through a wireless protocol (16) such as Bluetooth. Alternatively, the sensor (100) is connected to a control device through a wired protocol (18), such as MODBUS, and based on the detected signals displays the status of the condensate pump (200).

In an embodiment, the sensing device (100) detects and indicates failure as well as normal satisfactory working conditions of the condensate pump (200).

In another embodiment, the sensing device (100) detects and indicates failure as well as normal satisfactory working conditions and indicates failure through an alarm or siren to alert the user to take corrective action.

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 ADVANCES AND ECONOMICAL SIGNIFICANCE

The present disclosure described herein above has several technical advantages including, but not limited to a system for failure detection in a condensate pump, that:

• detects and indicates flooding in a condensate pump due to pump mechanism failure;

• detects and indicates flooding in a condensate pump due to incorrect pump selection or undersized pump selection;

• shares the working status of the condensate pump through wired & and wireless communication;

• detects and indicates the normal condition of the condensate pump;

• prevents damage to process equipment due to flooding failure in the condensate pump; • helps in saving water treatment cost, and heating costs; and

• is environment-friendly.

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.

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.