Patent Application
20250137663
The present invention is in the technical field of insulating covers and pertains more particularly to a cover with sensors and a capability of wireless reporting.
The use of steam traps in heat exchanger and steam transfer systems is well known. It is also well known that steam traps need regular maintenance, and for this reason permanent insulation is typically not used with steam traps, and the lack of insulation allows heat to escape from surfaces of the traps, resulting in significant energy loss in a system.
It is also well known that there is a need for monitoring of steam traps to provide quick response to trap failure. Steam trap surveys require manual temperature sensing at each trap to determine if the trap is blowing live steam, is plugged or is rapidly cycling, which may indicate an imminent failure. Conventionally there are a number of solutions for manual steam trap monitoring, but the conventional solutions require sensors mechanically or permanently fixed directly to the traps or plumbing near the traps. These solutions require shutdown for installation, maintenance, and also usually have exposed wires. This is a problem when electronics and equipment are exposed to the environment and not protected, as temperature and other data may not be recorded accurately.
What is clearly needed are removable covers with integrated sensors for steam traps and integrated wireless apparatus for transmission of data from sensors to a central base station.
In one embodiment of the invention a steam trap cover is provided, comprising a front panel, a back panel, a top panel, and a first and a second end panel joined together along panel edges forming a substantially rectangular enclosure open at the bottom, and a bottom panel joined along one lower edge of the front or the back panel, such that the bottom panel may be opened or closed, the first and second end panels each having a circular opening and a slit from a bottom edge of the end panel into the circular opening.
The steam trap cover is characterized in that with the bottom panel open and the slits in the end panels separated the cover is adapted to be placed over a steam trap having an inlet and an exit pipe until the entrance and the exit pipe are enclosed in the circular openings, after which closing the bottom cover completely encloses the steam trap.
In one embodiment he cover further comprises a first pipe clip carrying a first thermocouple temperature sensor with a first conductor from the first thermocouple temperature sensor and a second pipe clip carrying a second thermocouple temperature sensor with a conductor from the with a second conductor from the second thermocouple temperature sensor, the first and second conductors leading to a wireless transmitter in a transmitter pocket affixed to a surface of the back cover. Also, in one embodiment the cover further comprises a power supply providing electrical power to the wireless transmitter. In one embodiment the power supply comprises a thermo-electric generator integrated with the top panel, the thermo-electric generator coupled to a cold sink outside the top panel and a hot sink inside the steam trap cover below the top panel. And in one embodiment the cover further comprises a closure panel joined to one upper edge of the transmitter pocket adapted to close a top opening of the transmitter pocket.
In one embodiment the cover further comprises an identity tag joined to the front or the back panel, the identity tag displaying an identity code unique to the steam trap cover. And in one embodiment the cover further comprises a QR code on the identity tag, the QR code providing information regarding a steam trap enclosed in the steam trap cover. In one embodiment the cover further comprises a temperature-sensitive color changing indicator affixed to the front or the back panel.
In another aspect of the invention a method for insulating a steam trap having an entrance and an exit pipe is provided, comprising providing a steam trap cover having a front panel, a back panel, a top panel, and a first and a second end panel joined together along panel edges forming a substantially rectangular enclosure open at the bottom, and a bottom panel joined along one lower edge of the front or the back panel, such that the bottom panel may be opened or closed, the first and second end panels each having a circular opening and a slit from a bottom edge of the end panel into the circular opening, enclosing the steam trap by the cover by opening the bottom panel, separating the slits in the end panels, placing the steam trap cover down over the steam trap until the entrance and the exit pipe are enclosed in the circular openings, closing the slits in the end panels and closing the bottom cover.
In one embodiment the method further comprises providing a first pipe clip carrying a first thermocouple temperature sensor with a first conductor from the first thermocouple temperature sensor and a second pipe clip carrying a second thermocouple temperature sensor with a second conductor from the second thermocouple temperature sensor, and coupling the first and second conductors to a wireless transmitter in a transmitter pocket affixed to a surface of the back cover of the steam trap cover. Also, in one embodiment the method further comprises providing a power supply providing electrical power to the wireless transmitter. In one embodiment the method comprises providing the power supply as a thermo-electric generator integrated with the top panel, the thermo-electric generator coupled to a cold sink outside the top panel and a hot sink inside the steam trap cover below the top panel. In one embodiment the method further comprises providing a closure panel joined to one upper edge of the transmitter pocket, the closure panel adapted to close a top opening of the transmitter pocket. And in one embodiment the method further comprises joining an identity tag to the front or the back panel, the identity tag displaying an identity code unique to the steam trap cover.
In one embodiment the method further comprises displaying a QR code on the identity tag, the QR code providing information regarding a steam trap enclosed in the steam trap cover. And in one embodiment the method further comprises affixing a temperature-sensitive color changing indicator to the front or the back cover.
In yet another aspect of the invention a heat exchange system is provided, comprising a plurality of steam traps connected in the system with each steam trap having an entrance and an exit pipe, a plurality of removable steam trap covers each having a front panel, a back panel, a top panel, a bottom panel and a first and a second end panel joined together along panel edges forming an enclosure, the steam trap covers each further comprising a first pipe clip carrying a first thermocouple temperature sensor with a first conductor from the first thermocouple temperature sensor and a second pipe clip carrying a second thermocouple temperature sensor with a second conductor from the second thermocouple temperature sensor, the first and second conductors leading to a wireless transmitter in a transmitter pocket affixed to a surface of the back cover, the steam trap covers enclosing individual ones of the plurality of steam traps, and a central digital hub having wireless communication circuitry coupled to a processor executing software, and a data repository. The thermocouple temperature sensors at each steam trap having a steam trap cover in the system measure temperature of the inlet and exit pipes, the wireless transmitters in the transmitter pockets transmit the measured temperatures to the wireless communication circuitry, and the processor executing the SW determines condition or failure of each steam trap having a steam trap cover.
In one embodiment of the system each steam trap cover in the system has an identity tag joined to the front or the back panel, the identity tag displaying an identity code unique to the steam trap cover, and to the steam trap covered. Also in one embodiment the identity tag on each steam trap cover further comprises a QR code providing information regarding the steam trap enclosed in the steam trap cover. And in one embodiment each steam trap cover in the system has a temperature-sensitive color changing indicator affixed to the front or the back cover.
There are a relatively wide variety of steam traps known in the art, and different sorts and styles are used for specific purposes. Removable insulating covers with integrated electronics in embodiments of the present invention are useful with substantially all sorts of steam traps.
Cover 200 has a top panel 201 through which a cold heat sink 214 contacting a thermo-electric generator 215 is integrated. There is a hot heat sink 216, not seen in
Cover 200 has a back panel 202, a front panel identified by 203, pointing to an inside surface of the front panel, and two end panels, one end panel 204 of which is seen in
A bottom panel 212 is engaged along one edge of back panel 202 in a manner that allows the bottom panel to be rotated open or closed. There is a hook and loop fastener pad 213a on a retainer strap 223 on one lower edge of front panel 203 and a compatible hook and loop fastener pad 213b on bottom panel 212, such that, with the bottom panel closed, retainer strap 212 may be closed over the bottom panel and the fastener strips engaged, to hold the cover closed over a steam trap. The hook and loop fastener pads in one embodiment may be Velcro™ pads.
A wireless temperature transmitter 208 is carried in a transmitter pocket 205 implemented on the back cover and has an antenna 209. Pocket 205 has a closure panel 206 with a hook and loop fastener pad 207b positioned to engage a hook and loop fastener pad 207a on the top panel when the closure panel is closed. There is a cut-out in the closure panel for the antenna 209. The hook and loop fastener pads in one embodiment may be Velcro™ pads.
An electronic temperature sensing device or temperature sensor 217, mounted to a pipe clip 218 is connected by conductor 219 to electronics for wireless temperature transmitter 208, such that real-time temperature readings on the incoming steam pipe may be recorded and transmitted wirelessly to a central hub. A similar temperature sensor 220 mounted to a pipe clip 221 is connected by a conductor 222 to the wireless temperature transmitter at the outlet end of the cover, to monitor temperature of exit pipe 102. The temperature sensors may be any one of a thermocouple, resistance temperature detector (RTD) or thermistor. Additionally, an ambient air temperature sensing device 225 is attached at the top of cover 200. The ambient air temperature may be used to get a more accurate reading of temperatures at the steam trap. A vibration or sonic sensor 226 is also positioned at the top cover. Data from both sensors 225 and 226 may be sent to a remote location from the wireless transmitter 208.
Cover 200 in an embodiment of the invention is assembled from layered panels which in one embodiment are stitched together. All panels have an outer layer of PTFE-impregnated fiberglass fabric or similar industrial material and an inner layer of semi-rigid glass fiber cloth. An inner surface of back panel 202 at the region of the transmitter pocket 205 has an additional layer of aluminized fiberglass heat shield with the reflective surface toward the inside, for additional protection of the transmitter and electronics in the transmitter pocket.
Front panel 203 has a temperature-sensitive color changing indicator 303 mounted centrally to the cover, that changes from green to red at a predetermined temperature, indicating that the enclosed trap is hot and operating correctly. A metal equipment tag 301 including a unique serial number and a unique QR code 302 is mounted and may be read by a cellphone camera (not shown) which may provide details about the specific trap, including make, model, location, operating parameters, installation date location on a map or P&ID and a photo. Every steam trap in a system has a specific cover for just that trap. In this manner one need not lift the cover to get a temperature reading and may identify the trap and read the temperature and sonic or vibration data without lifting the insulating cover. A maintenance worker may simply walk by and glance at the status of the steam trap as displayed on the outside of the cover. It is important to be able to do a check for maintenance of the steam trap without lifting the cover as temperatures may reach dangerous levels. Viewing data from the outside of the cover is very advantageous.
An important purpose of the steam trap cover in embodiments of the invention is to insulate steam traps in a heat exchanger system reducing energy loss. Another important purpose is to transmit temperature readings at a plurality if steam traps, in some embodiments every steam trap, to a central hub to monitor conditions and status of the steam traps.
Covers 200a through 200n may represent a large number of steam trap covers in a system, and the cover for each steam trap in an embodiment of the invention is unique to that steam trap. The cover may have a metal tag 301 including a unique serial number and a unique QR code 302 as described above, which may be read by a cellphone camera (not shown) which may provide details about the specific trap, including make, model, location, operating parameters, installation date location on a map or P&ID and a photo. Every steam trap in a system has a specific cover for just that trap.
Covers 200a through 200n in this example each communicate wirelessly with central hub 601 through the local transmitter 208 to wireless communication circuitry 604 coupled to processor 602 in the central hub. The temperatures collected by the temperature sensors mounted on pipe clips snapped onto both the inlet and the exit pipe at each steam trap sensors are transmitted to processor 602. Processor 602 executes software 605 which may be a program that is adapted to provide intelligence to a knowledgeable worker of the system as to the condition and predictive failure mode of each of the steam traps.
A skilled person will understand that the embodiments described in this specification are entirely exemplary and not limiting to the scope of the invention, which is limited only by the claims that follow.
