Liquid Condensate Collection and Drain Apparatus for Compressed Air-Gas Systems and Method Therefore

The present invention provides a method, process and apparatus for effectively draining liquid condensate from compressed air/gas systems. The draining apparatus having a means to evacuate collected condensate from a chamber reservoir without a loss of system compressed air or gas in its discharge of the drainage to assure that contaminates and particulates in the liquid condensate do not collect and build-up in its inner chambers and orifices. The device reduces energy consumption as it relates to wasted compressed air/gas in the purging of liquid condensate.

DETAIL DESCRIPTION OF THE INVENTION

InFIG. 1ais shown a flow diagram10aof the preferred embodiment of the present invention having a chamber housing12with a reservoir14, an inlet port16and an outlet port18. The chamber housing12further has an inspection port20and a forth port22. Mounted to the chamber housing12inlet port16is a normally open inlet solenoid valve24and to the outlet port18, a normally closed outlet solenoid valve26. Further mounted to the inlet solenoid valve24is a pressure regulator28with an integral pressure gauge30and a pressure adjustment means32. Finally, a condensation entry device connection34and a collected condensation discharge device connection36.

Condensation would enter the drain system (illustrated in the flow diagram10a) at the device connection34and pass through the pressure regulator28. The condensation would continue through the normally open solenoid valve24and into the inlet port16. The condensation would collect within the reservoir14of the chamber housing12. At an appropriate time (as will be discussed later), the normally closed outlet solenoid valve would open and allow any collected condensation within the reservoir to discharge through the outlet port18, solenoid valve26and discharge out the device connection36for drainage. It is important to understand that the when the normally closed outlet solenoid valve26is energized open (allowing flow through it), the normally open inlet solenoid valve24is energized to close (blocking flow through it). There would be a small pressurized ‘air/gas’ ullage space above the collect condensate within the reservoir14(this will be more fully disclosed later), that when the outlet is discharged, the condensate would flow freely out. Again it is important to understand that since no additional compressed air/gas can reenter the chamber12, because the inlet solenoid valve24is energized to the closed position, the outlet solenoid valve26can be left open for drainage as long as is desired with no air loss.

Referring back to the pressure regulator28, in this embodiment of the present invention, has an adjustment means32to step-down the compressed air/gas system pressure (for example 100 PSIG), to a drain device operating pressure (for example 30 PSIG), as set on the integral pressure gauge30. The drain device of the flow diagram10acan be set to any pressure for use. The 100/30 ratio in the above example would represent a typical compressed air installation. But the adjustment32could just as easily be set to have drain operating pressure of 60 PSIG or 20 PSIG. Further, in the case of a ‘high pressure’ installation, where pressures could be 300, 700 or even a 1000 PSIG at the device connection34, the drain operating pressure could still be within a low safe range, for example under 100 PSIG. The usage of the inspection port20and the forth port22will be discussed later in the patent.

We move now to the first alternate embodiment ofFIG. 1b, where is shown a flow diagram10b. In this embodiment, is used a fixed reducing pressure regulator38. The fixed reducing regulator38could be, for example, one with a ratio of 100 PSIG to 30 PSIG. And, will not have any adjustment means or pressure display means (32or30respectively) as in the system of the flow diagram10adevice above. All other aspects of operation of the first alternate embodiment in flow diagram10bwork similarly as was disclosed in the flow diagram10aofFIG. 1aabove. It is important to understand that any ratio of pressure reduction, as would be suitable for any given drain device installation, could be used by selecting a pressure reduction regulator as manufactured for such pressure reduction (for example 1000 to 60 PSIG).

Moving now to the second alternate embodiment ofFIG. 1c, where is shown a flow diagram10c. In this embodiment, the use any pressure regulating means has been eliminated. That is, adjustable pressure regulator28and fixed reduction pressure regulator38are not present in the device, and will accept whatever line pressure is present on the compressed air/gas system it is connected to at the condensation device entry connection34. Again, all other aspects of operation of the second alternate embodiment in flow diagram10cwork similarly as was disclosed in the flow diagram10aofFIG. 1aabove. In this configuration, the device of the flow diagram10c, operating at a higher pressure for example 100 PSIG, the device would need the consideration for such pressure, but will function suitably and safely. More on this subject will be disclosed later.

FIG. 2ais a perspective view showing the outside of the drain chamber universal shell S. The shell S has a threaded upper port40and a threaded lower port42, a coupling hole44on each corner and a blind mounting hole46on the bottom two ends. The ports40and42can be threaded either on the inside or outside making them either female or male connections, as may be desired in manufacturing. The preferred embodiment is ½ inch NPT female. The blind mounting holes46have female threads that is ¼ inch NPT female. The shell is of molded construction of high strength, fiber filled nylon polymer. (such as DuPont's ST801).

FIG. 2bis a perspective view showing the inside of the drain chamber universal shell S having a flat surface48, an O-ring groove52, and inner space50, with an access holes54and56joined to the ports40and42respectively inFIG. 2a. To make a complete chamber, two identical universal shells S are assembled with their flat surfaces48mated to one another, and with an O-ring inserted into the O-ring groove52. The unit then would be secured by nut & blots used in each of the four coupling holes44. The preferred embodiment of the present invention, the shell is of fiber filled nylon polymers as stated above, but could be constructed with any other suitable material such as aluminum cast, or, even welded carbon or stainless steel to form a chamber/reservoir. In any case, a bust value for a pressure test would be expect to be between 1400 to 1600 PSI, and a normal operating pressure of 150 to 200 PSI. More will be disclosed on the construction of the chamber12in the later figures of the present patent.

FIG. 3is a top plainer view of the preferred embodiment in the flow diagram ofFIG. 1a, showing the input port16and output port18as mechanical representations16aand18arespectively. Two universal shells S are joined together and secured with a bolt58and a nut60at each of the four corners. The drain device can be mounted to equipment via a mounting bracket62that is attached to each shell S with a bolt64(that mates with blind holes46). In the preferred embodiment bolts58and64, and nuts60are all ¼ inch NPT. A hole66in the mounting bracket62is suitable for mounting the drain device, either horizontal or vertical, to the external compressed air/gas equipment.

The mechanical representations of the flow diagram symbols ofFIG. 1ainlet solenoid valve24, the outlet solenoid valve26, pressure regulator28(with adjustment means32and pressure gauge30), condensation entry device connection34and condensation discharge connection36are indicated inFIGS. 3as24a,26a,28a,30a,32a,34a, and36arespectively.

FIG. 4is a front plainer view of the device inFIG. 3showing additional device ports20aand22a.20aand22aare mechanical representations of the flow diagram symbols ofFIG. 1ainspection port20and forth port22. The inspection port20ahas a plug68inserted to close off the opening. The plug68may be removed from time to time to inspect for build-up on sediment and slug that may be deposited after extended period of use from the condensate. The forth port22amay be used for a number of optional functions. One such function is to use forth port22aas a vent for pressure equalization (not shown for clarity of presentation). Another possible function could be as a means for instrumentation (pressure and temperature) or sensors such as a level sensor, also not shown. If no optional feature is used, the forth port22awould be plugged-off as is plug68on the inspection port20.

FIG. 5is a side perspective view of the preferred embodiment ofFIGS. 3 and 4showing all the components fully assembled.

FIG. 6is an illustration of the present invention ofFIG. 5showing in an exploded view with each component separated and dashed line indicating their relationship to one another. An O-ring70is shown how it would be seated in the groove52of flat surface48in the universal shells S. The reference ‘A’ indicate where the cross sectional view is located in the up-comingFIG. 7.

FIG. 7is an illustration ofFIG. 6showing a cross sectional view ‘A’ of the main body housing. The O-ring70properly seated creates a pressure-tight vessel chamber12awith a reservoir14a(12aand14aare mechanical representations of the chamber12and reservoir14symbols, respectively, illustrated inFIG. 1.) The reservoir14ahas a liquid level72, and ullage space74and a liquid space76. Liquid condensate78trickle-in to the reservoir14a, as was described earlier, through pressure regulator28a, inlet solenoid valve24aand inlet port16a. When level72rises over time, for example fifteen or twenty minutes, the normally open inlet solenoid valve CLOSES (isolating the drain system from the upstream line pressure) and the normally closed outlet solenoid valve OPENS when they are energized.

The energizing of these solenoids are accomplished by an electric timing device (such as a programmable logic controller or discrete electronic device designed for such timing) not shown because they are of conventional means and are common.

In operation, when the inlet and outlet solenoids are both energized, the collected condensation76in the reservoir14a, is jettisoned out through outlet port18aand outlet solenoid26aand discharged down a disposal drain as drainage. Because the inlet solenoid valve is closed, there is no loss of precious compressed air/gas, ever, and the outlet solenoid can be left OPEN as long as necessary to fully empty the reservoir. It is important to understand that the residual compressed air/gas, in the ullage space74will help propel the liquid condensation out the system because of the differential pressure between the ullage space and ambient pressure of the deposal drain. Since there is no loss of precious compressed air/gas, ever, the inlet and outlet solenoid valves can be larger in orifice size; allowing complete expulsion of particulates and contaminates in the condensation avoiding sediment build-up in the reservoir the leads to expensive device malfunction and high maintenance, as is common in prior art drain devices. However, the inspection port20aaffords easy viewing the reservoir bottom, at maintenance intervals, and, should it every be necessary to open the chamber12a, the system can be fully disassembled and re-assembled (by simply removing the four coupling bolts58and nuts60).

While the invention has been particularly described and illustrated in detail with reference to the preferred embodiment and two alternate embodiments, it should be understood by those skilled in the art that equivalent changes in form and detail may be made without departing from the true spirit and scope of the invention as claimed, except as precluded by the prior art. The embodiments of the invention for which an exclusive privilege and property right is clamed are defined as follows: