Energy storage and control system for pipe flow control

Abstract

A fluid control system (100, 200) for controlling a flow of a process fluid can include an actuator (104, 204) and an energy storage system (102, 202). The actuator can be provided to actuate the valve (120) in order to control the flow of the process fluid, and the energy storage system can actuate the actuator. An energy storage system (100, 200) can include an accumulator (106, 206) in fluid communication with an actuator and a manual pump (108, 208) arranged to charge the accumulator (106, 206).

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 396,439 (filing date August 9, 2022), U.S. Provisional Patent Application No. 63 / 492,389 (filing date March 27, 2023), and U.S. Provisional Patent Application No. 63 / 492,397 (filing date March 27, 2023), all of which are incorporated herein by reference in their entirety. Background Art

[0003] Fluid control systems can be used in a variety of industrial, commercial and other environments to regulate, protect, isolate or maintain pipes, conduits or other containers and the flow of fluids therein. In some applications, it can be advantageous to manage or control fluid flow in processing systems where certain power sources are unavailable. Summary of the invention

[0004] Some embodiments of the present invention provide a fluid control system for controlling the flow of a treatment fluid through a pipeline. The fluid control system can include a valve, an actuator, and an energy storage system. The valve can move between an open and a closed position to control the flow of a treatment fluid through a portion of a pipeline. The actuator can be configured to move the valve between an open position and a closed position. The energy storage system can be in fluid communication with the actuator to drive the actuator. The energy storage system can include a single accumulator and a pump. The single accumulator can have a first chamber and a second chamber. The first chamber can be in fluid communication with the actuator, and the second chamber can be in fluid communication with the pipeline so that the second chamber can receive a pressurized treatment fluid from the pipeline. The pump can be configured to pump hydraulic fluid into the first chamber of the single accumulator to charge the single accumulator against the pressure of the pressurized treatment fluid in the second chamber. The energy storage system can determine a fully charged state and a fully discharged state. In the fully charged state, the first chamber of the single accumulator can include a maximum operating volume of hydraulic fluid, and the second chamber can include a minimum operating volume of pressurized treatment fluid. In the fully discharged state, the first chamber of the single accumulator includes a minimum operating volume of hydraulic fluid and the second chamber includes a maximum operating volume of pressurized process fluid.

[0005] In some embodiments, the fluid control system can include a manual pump that can be manually operated without electrical power.

[0006] In some embodiments, the fluid control system can include an energy storage system. The energy storage system can include a pump in fluid communication with the actuator and the fluid reservoir. Operation of the pump can place the energy storage system in a charging state, wherein the pump pumps hydraulic fluid from the fluid reservoir into a first chamber of the single accumulator.

[0007] In some embodiments, the fluid control system can include an energy storage system that defines a drain state. In the drain state, hydraulic fluid can flow from a first chamber of a single accumulator to the actuator, and pressurized process fluid can flow from a conduit into a second chamber of the accumulator.

[0008] In some embodiments, the fluid control system can include a directional control valve to direct hydraulic fluid from a first chamber of a single accumulator to an actuator to move the actuator in a first direction, and to direct hydraulic fluid from a first chamber of the single accumulator to the actuator to move the actuator in a second direction.

[0009] In some embodiments, the fluid control system may include an actuator. Moving the actuator in a first direction can open the valve, and moving the actuator in a second direction can close the valve.

[0010] In some embodiments, the fluid control system may include an actuator. Moving the actuator in a first direction and moving the actuator in a second direction can provide a valve event. A single accumulator can be configured to supply flow for less than two valve events before reaching a fully discharged state.

[0011] In some embodiments, the fluid control system can include an actuator. Moving the actuator in a first direction and moving the actuator in a second direction can provide a valve event. A single accumulator can be configured to provide flow for at least three valve events before reaching a fully discharged state.

[0012] In some embodiments, a fluid control system can include a hydraulic fluid contained within a first flow system and a process fluid contained within a second flow system that is fluidly closed to the first flow system.

[0013] In some embodiments, the fluid control system can include a portable pump connected in parallel with the main pump. The portable pump can be configured to pump hydraulic fluid to a first chamber of the single accumulator to charge the single accumulator against the pressure of pressurized process fluid in a second chamber of the single accumulator.

[0014] In some embodiments, the fluid control system can include an energy storage system that allows a single accumulator to transition from a fully charged state to a fully discharged state without operating a pump.

[0015] Some embodiments provide an energy storage system for driving an actuator. The actuator can be configured to move a valve between an open position and a closed position to control the flow of a process fluid through a portion of a pipeline. The energy storage system can include an accumulator having a first chamber and a second chamber. The first chamber can be in fluid communication with the actuator, and the second chamber can be in fluid communication with the pipeline so that the second chamber can receive pressurized process fluid from the pipeline. A manual pump can be configured to pump hydraulic fluid into the first chamber of the accumulator to charge the accumulator against the pressure of the pressurized process fluid in the second chamber.

[0016] Some embodiments provide an energy storage system for driving an actuator. The actuator can be configured to move a valve between an open position and a closed position to control the flow of a process fluid through a portion of a pipeline. The energy storage system can include a container that defines an internal chamber in fluid communication with the actuator and a pump. The pump can be configured to fill the container with a control fluid against pressure applied by the process fluid. A second can be configured to sense a fluid level of the control fluid within the container and to signal whether the control fluid is at a maximum operating volume. The maximum operating volume can be less than the total volume of the internal chamber of the container.

[0017] In some embodiments, an energy storage system can include an accumulator or other container that is not arranged to operate in parallel with another accumulator or other container.

[0018] In some embodiments, the energy storage system can include a manual pump configured to pump hydraulic fluid into the container to fill the container against the pressure of the process fluid. Operation of the manual pump can place the container in a filled state in which the pump pumps hydraulic fluid from the fluid reservoir into the container.

[0019] In some embodiments, the energy storage system can include a reservoir that is in a draining state when hydraulic fluid flows from the reservoir to the actuator and pressurized process fluid flows from the conduit into the reservoir.

[0020] In some embodiments, the energy storage system can include a directional control valve to direct hydraulic fluid from a first chamber of the container to the actuator to move the actuator in a first direction, and to direct hydraulic fluid from the first chamber of the container to the actuator to move the actuator in a second direction.

[0021] In some embodiments, the energy storage system can include a process fluid that is fluidly separated from the hydraulic fluid.

[0022] In some embodiments, the energy storage system can include a container that is a single accumulator (e.g., not two accumulators in parallel). In some embodiments, the energy storage system can include only a single accumulator (i.e., not multiple accumulators, nor multiple accumulator volumes or chambers arranged to operate in parallel within a device or system).

[0023] Some embodiments provide a method of actuating a valve of a pipeline for a process fluid. The method can include charging an accumulator. Charging the accumulator can include manually pumping a control fluid from a fluid reservoir to fill a first chamber of the accumulator with the control fluid. The accumulator can thus be charged to discharge, thereby actuating an actuator of the valve by the control fluid flowing out of the first chamber, the accumulator being powered by the pressure of the process fluid in the pipeline.

[0024] In some embodiments, a method of actuating a valve of a pipeline for a process fluid can include discharging an accumulator. Discharging the accumulator can include: signaling hydraulic fluid to flow from a first chamber of the accumulator to an actuator; and sending process fluid from the pipeline to a second chamber of the accumulator. Discharging the accumulator does not include operating a pump. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the subject matter of the invention and, together with the description, serve to explain the principles of the embodiments of the invention:

[0026] Figure 1 is a schematic diagram of a fluid control system according to an embodiment of the present invention, the fluid control system includes an actuator, an accumulator and a pump.

[0027] Figure 2 yes Figure 1 Schematic diagram of the fluid control system in the filling state.

[0028] Figure 3 yes Figure 1 Schematic diagram of a fluid control system in a discharge state.

[0029] Figure 4 is a schematic diagram of a fluid control system according to an embodiment of the present invention, the fluid control system including an actuator, an accumulator, and a battery-operated pump.

[0030] Figure 5 is a schematic diagram of a fluid control system according to an embodiment of the present invention, the fluid control system including an accumulator and a motor control device.

[0031] Figure 6 yes Figure 5 A side view of the accumulator.

[0032] Figure 7is a schematic diagram of a fluid control system according to another embodiment of the present invention, the fluid control system includes an accumulator and a motor control device.

[0033] Figure 8 yes Figure 7 A side view of the accumulator.

[0034] Fig. 9 is a schematic diagram of a fluid control system according to another embodiment of the present invention, the fluid control system includes a container, a motor and a motor control device.

[0035] Fig. 10A It indicated Fig. 9 Schematic diagram of a container, wherein the control fluid level is below the maximum operating fluid volume and the motor is running.

[0036] Fig. 10B It indicated Fig. 9 Schematic diagram of a container in which the control fluid level is at a maximum operating volume and the motor is stopped. DETAILED DESCRIPTION

[0037] The following description is provided to enable those skilled in the art to make and use embodiments of the subject matter of the present invention. In view of the benefits of the present invention, it will be apparent to those skilled in the art that various variations of the illustrated embodiments are known, and without departing from embodiments of the present invention, the principles of this article can be applied to other embodiments and applications. Therefore, the embodiments will not be limited to the illustrated embodiments, but should be based on the widest range consistent with the principles and features disclosed herein. The following detailed description will be read with reference to the accompanying drawings, and the same elements in different drawings have the same reference numerals. The accompanying drawings, which are not necessarily drawn to scale, represent selected embodiments and are not intended to limit the scope of the embodiments described herein. Those skilled in the art will recognize that the examples provided herein have many advantageous alternatives and fall within the scope of embodiments of the present invention.

[0038] Before explaining any embodiment in detail, it should be understood that the subject matter of the present invention is not limited in its application to the details of the structure and arrangement of the components described in the following specification or shown in the following drawings. The subject matter of the present invention can have other embodiments and can be practiced or executed in various ways. In addition, it should be understood that the words and terms used herein are for illustrative purposes and should not be considered as limitations. "Including", "including" or "having" and their variations used in this article are meant to include the items listed later and its equivalents and additional items. Unless otherwise specified or limited, the terms "installation", "connection", "support" and "connection" and their variations will be widely used and include direct and indirect installation, connection, support and connection. Moreover, "connection" and "connection" are not limited to physical or mechanical connections or connections.

[0039] As briefly described above, fluid control systems can be used in a variety of industrial, commercial and other environments to control the flow of fluids through pipes, conduits or other containers. For example, some processing systems (including offshore drilling, oil fields, natural gas transmission pipelines, etc.) may (occasionally) require valve actuation at remote or difficult-to-access locations. Such remote locations may lack a power source and therefore would benefit from non-electric valve actuation.

[0040] Embodiments can provide a fluid control system having an energy storage system configured to drive a valve. Some fluid control systems described herein can drive a valve without electricity or other non-manual power sources. In particular, embodiments described herein can provide an energy storage system including a manually operated pump configured to charge an accumulator, and in some embodiments, a single accumulator is charged (i.e., not another accumulator in parallel or multiple accumulator chambers arranged to operate in parallel with each other within a device or system). The accumulator can be configured to store potential energy that can drive an actuator upon receiving a signal requesting a valve event. After a discharge event of the accumulator in preparation for another signaled valve event, a manual pump can be used to recharge the accumulator with a control fluid.

[0041] Typically, adding energy to a system (e.g., via an electric pump) can increase the thermal energy of the work or control fluid therein, which can cause thermal expansion and / or pressure changes in the fluid. Therefore, in fluid control systems that employ control fluid to charge (and discharge) an accumulator to drive an actuator, it is important to control, monitor, reduce, and / or eliminate thermal expansion within the system to help ensure a fully charged state of the accumulator.

[0042] Other embodiments can provide a fluid control system having an energy storage system that is configured to be recharged by a motor or other energy supplier (e.g., an electric pump) while compensating for thermal expansion. In particular, the energy storage system can include built-in thermal compensation. For example, the volume of a hydraulic fluid (or other control fluid) can fluctuate based on temperature or pressure changes. An embodiment of the present invention provides an energy storage system that compensates for thermal expansion of a hydraulic fluid within a single container (e.g., a single accumulator). The energy storage system can include a motor control device that is connected to the motor. The motor control device can send an open or closed signal to the motor based on the fluid height in the accumulator or container to refill the accumulator or container with hydraulic fluid while maintaining a thermally compensated gap volume within the accumulator or container to prevent fluid overflow or damage to the device due to over-pressurization.

[0043] Typically, monitoring and / or compensating for thermal expansion of a control fluid in conventional fluid control systems (particularly using external or auxiliary thermal volume controllers) can be expensive, time consuming, and inefficient. Accordingly, embodiments of the present invention can address these and other shortcomings of conventional fluid control systems.

[0044] Figure 1 A fluid control system 100 is shown according to an embodiment of the present invention. The fluid control system 100 can include an energy storage system 102 in communication with an actuator 104 (e.g., various known types of actuators to open and close various known types of valves). In the illustrated embodiment, the energy storage system 102 can include an accumulator 106 and a pump 108. When installed for operation, the fluid control system 100 can be in communication with a valve, such as a valve 120 (e.g., any of various known types of valves to control the closure of the associated flow). In the illustrated configuration, the valve 120 is in fluid communication with a process fluid flowing through a conduit 122. The valve 120 can be stroked by the actuator 104 to close (or open) the valve 120 and stop the process fluid from flowing through (or allow the process fluid to flow through) the conduit 122.

[0045] In some embodiments, the pipeline 122 can include a compressible fluid, such as natural gas, which flows through the pipeline 122 under high pressure, for example. The pipeline 122 can be used in various processing systems, and portions of the pipeline 122 (e.g., including the valve 120) can be located in a remote location where a power source (e.g., electric or pneumatic) may not be available or is expensive to obtain. In this regard, the fluid control system 100 according to embodiments of the present invention can operate substantially without power, and in particular, without power being supplied to the pump 108. Therefore, in some embodiments, the pump 108 is configured as a manual pump. However, other configurations are also possible, including, for example, with respect to Figure 4 described.

[0046] Continue to refer Figure 1 , the energy storage system 102 includes an accumulator 106 in fluid communication with a pump 108, which accumulator 106 can generally be configured as a container. The energy storage system 102 can also include a fluid reservoir 130 (e.g., having a fluid level observer 132). In the illustrated embodiment, the fluid reservoir 130 is located upstream of the pump 108 and downstream of the actuator 104. Generally, the fluid control system 100 provides a first closed-loop hydraulic system through which a control fluid travels. The energy storage system 102 within the fluid control system 100 can also include a series of valves (e.g., including a system bypass valve, a safety valve, a check valve, a directional valve, and an isolation valve) as well as one or more of an oil filter, a reservoir drain, and a pressure gauge (e.g., not shown or numbered).

[0047] The energy storage system 102 can include a control fluid that can be delivered to and from the accumulator 106 and the reservoir 130 by a pump 108. In some embodiments, the control fluid can be a hydraulic fluid, although other incompressible fluids are also possible. In use, the pump 108, which is a manual pump in a preferred embodiment, can draw the control fluid from the fluid reservoir 130 and discharge the control fluid into a first chamber 138 of the accumulator 106. The accumulator 106 can also include a second chamber 140 that is opposite to the first chamber 138 and fluidly separated from the first chamber 138 (e.g., by a piston or a bladder). The second chamber 140 is arranged to be filled with a (high pressure) process fluid from the pipeline 122. Therefore, the second chamber 140 is in fluid communication with the pipeline 122 upstream of the valve 120 and provides a second flow system that is fluidically closed to the first system (i.e., including the first chamber 138, the pump 108, the reservoir 130, etc.).

[0048] Figure 2 1 shows the charge state of the energy storage system 102. In particular, when the control fluid is drawn from the fluid reservoir 130 by the pump 108, the accumulator 106 is charged against the gas pressure of the process fluid in the conduit 122 (i.e., the fluid is temporarily charged into the first chamber 138 against the pressure of the process fluid in the second chamber 140). As the control fluid fills the first chamber 138 of the accumulator 106, the potential energy stored in the accumulator 106 increases. When the accumulator 106 is in a fully charged state (i.e., at maximum potential energy), the first chamber 138 is at a maximum operating volume (i.e., the maximum fluid volume of the chamber 138 for any state of the accumulator 106 when in service), and the second chamber 140 is at a minimum operating volume (i.e., the minimum fluid volume of the chamber 140 for any state of the accumulator 106 when in service).

[0049] In general, the potential energy stored in the accumulator 106 can be used with various actuator controls, including an actuator (e.g., the actuator 104) configured to stroke a pipeline valve when no electrical service is available. In the illustrated embodiment, the first chamber 138 of the accumulator 106 is also in fluid communication with the actuator 104. When a signal is received by the fluid control system 100, the accumulator 106 can release some (or all) of its potential energy to drive the actuator 104. The actuator 104 can then perform a specific valve event, such as closing or opening the valve 120. In some embodiments, the signal can be received by various known types of directional control valves (not shown) that are part of or in fluid communication with the actuator 104. The control valve can direct fluid from the first chamber 138 of the accumulator 106 to the actuator 104.

[0050] In use, an operator can physically travel to the fluid control system 100 to manually operate the pump 108 of the energy storage system 102 to charge the accumulator 106 (i.e., by the operator directly inputting mechanical energy into the fluid control system 100 or by using a powered or unpowered hand tool to operate the pump 108). If desired, the fluid level sight 132 can be used to measure the volume of the control fluid in the first chamber 138, and therefore the potential energy of the accumulator 106. For example, the fluid level sight 132 can indicate when the first chamber 138 is filled with control fluid to reach a maximum operating volume, which can correspond to a fully charged state of the accumulator 106. In other embodiments, one or more of the accumulator 106 or the reservoir 130 can include additional or alternative measuring instruments to monitor the state of the accumulator 106, such as a dipstick or other graduated measuring device.

[0051] As described above, the pump 108 of the present embodiment can be a manual pump. Among other benefits, the use of a manual pump can reduce (e.g., eliminate) excess energy (i.e., heat) that can be added to the energy storage system 102 when the pump 108 charges the accumulator 106. For example, an electric pump or other non-manual pump can add thermal energy to the control fluid moving through such a pump, at least significantly more than is typically the case with a manual pump. However, thermal energy can be introduced into the system by other events, including changes in ambient temperature. In this regard, one or more pressure relief valves can be incorporated into the energy storage system 102 to compensate for volume and pressure changes in the control fluid.

[0052] Typically, an increase in the thermal energy of a control fluid can affect the pressure of the control fluid and negatively affect the potential energy of such control fluid, which can be stored, for example, in an accumulator. Accordingly, the use of a manual pump according to some embodiments of the present invention can result in improved operating efficiency and energy storage capacity. Similarly, the use of a manual pump can result in a system that requires fewer or less complex components. For example, in some systems where thermal energy in a control fluid is increased by a non-manual pump, a thermal compensation device is used to compensate for or otherwise adjust for pressure changes and other fluctuations in the fluid. Some embodiments can operate efficiently without such a thermal compensation device, or at least operate efficiently when the compensation system has a smaller volume than a conventional design.

[0053] Therefore, embodiments of the present invention can advantageously reduce (or eliminate) excess energy in the control fluid of the energy storage system 102 by means of the manual pump 108. In this regard, embodiments of the present invention can provide a simplified energy storage system that does not require a thermal compensation device. Typically, a thermal compensation device can include various devices, including, for example, a thermal compensation accumulator or a thermal volume controller. A thermal volume controller can include, for example, a pressure switch or a second accumulator (e.g., arranged in parallel with the accumulator 106 fluid). Such a thermal compensation device can add various complexities to the fluid control system, such as increased costs, maintenance, repairs, and complex installation. In addition, an embodiment can provide a fluid control system having an energy storage system that allows a single accumulator to transition from a fully charged state to a fully discharged state without operating a pump. In conventional fluid control systems, a sensor device can trigger an electric pump in the discharge process, however, embodiments of the present invention allow pump operation independent of an actuator or other thermal volume controller.

[0054] In this regard, embodiments of the present invention can advantageously provide an unbranched flow path between the second chamber 140 of the accumulator 106 and the conduit 122. The unbranched flow path may not include flow to other operating devices of the energy storage system 102 (e.g., the second accumulator). However, the unbranched flow path (e.g., Figure 1-4 The non-operating components (shown as a passage extending between the second chamber 140 of the accumulator 106 and the conduit 122) can include non-operating components, such as filters or measuring instruments. In some embodiments, the unbranched flow path can be characterized as a series (i.e., not parallel) flow path extending between the second chamber 140 and the conduit 122. Other non-operating components can include components that, when removed from the system 100, will not affect the basic operation of the energy storage system 102.

[0055] Reference below Figure 3, representing a discharge state of the energy storage system 102. During operation in the discharge state, one or more valves can allow flow out of the first chamber 138, such as powered by pipeline pressure through the second chamber 140 being filled with pressurized process fluid from the pipeline 122. This flow into the second chamber 140 will force the control fluid to flow from the first chamber 138 of the accumulator 106 to the actuator 104, and the actuator 104 can accordingly initiate and complete the valve stroke on the valve 120. Therefore, generally, in the discharge state, some (or all) of the potential energy stored in the accumulator 106 is released. In some embodiments, the discharge of the accumulator 106 to power a valve event (or multiple valve events) can cause the accumulator 106 to be discharged to a fully discharged state. When the accumulator 106 is in a fully discharged state (i.e., minimum or zero potential energy), the first chamber 138 is at a minimum operating volume and the second chamber 140 is at a maximum operating volume. However, in some cases, the accumulator may not be fully discharged through operation in one valve event (or multiple valve events).

[0056] In some embodiments, the accumulator 106 can allow for multiple discharge events, so that the accumulator can drive the actuator 104 multiple times (i.e., stroke the valve 120 multiple times) before requiring recharging from the pump 108. For example, in some embodiments, the actuator 104 can include a directional control valve (not shown) that directs control fluid from the first chamber 138 of the accumulator 106 to move or stroke the actuator 104 in a first direction (e.g., clockwise), or directs control fluid from the first chamber 138 of the accumulator 106 to move or stroke the actuator 104 in a second direction (e.g., counterclockwise). Thus, in some embodiments, the accumulator 106 can be configured to partially discharge to close the valve 120, partially discharge to open the valve 120, and fully discharge to close the valve 120 (or otherwise similarly operate in multiple valve events).

[0057] Although it should be understood that the accumulator 106 and the fluid control system 100 can be configured to stroke the valve or otherwise actuate the valve 120 one or more times, in a preferred embodiment, the accumulator 106 can be configured to actuate the actuator 104 an odd number of times (e.g., 1 or 3 times). For example, the fluid control system 100 can be used to close the valve or otherwise restrict flow through the pipeline 122 in the event of a fault or other undesirable event associated with the process fluid and the pipeline 122. Considering that the fluid control system 100 can be used in a remote or inaccessible location, it is generally advantageous that the accumulator 106 will at least actuate the actuator 104 to actuate the valve 120 to a safe (e.g., closed) orientation before the accumulator 106 needs to be recharged. Therefore, in a preferred embodiment, the energy storage system 102 is configured to close the valve 120 before reaching a fully discharged state, or, for example, to close-open-close the valve 120 before fully discharged.

[0058] Figure 4 Another example configuration of a fluid control system 100 according to an embodiment of the present invention is shown. In the illustrated configuration, the energy storage system 102 can include an auxiliary power source 146. For example, in some embodiments, the auxiliary power source 146 can be configured as a battery-powered pump (e.g., a portable pump). The auxiliary power source 146 can include (or otherwise be powered by) a variety of power sources, including a battery (e.g., a truck battery), a battery-powered drill, or other portable battery that can be used to drive a pump to charge the accumulator 106. Typically, the auxiliary power source 146 can be a portable power source that an operator transports to a fluid control system 100 located in a remote location. The auxiliary power source 146 can be connected to the fluid control system 100 via a quick-connect system 148 that allows easy connection and disconnection between the auxiliary power source 146 and the fluid control system 100. For example, various known types of quick-connect valves or fittings can be arranged to communicate with the hydraulic system so that the auxiliary power source 146 (e.g., a pump) can be easily and temporarily connected in parallel with the hand pump 108.

[0059] In some embodiments, the auxiliary power source 146 (which can include a battery-powered pump) can be removed from the energy storage system 102. When the accumulator 106 needs to be recharged, such a pump can be brought to a remote location of the fluid control system 100 and removed when the accumulator 106 is charged. In this regard, the auxiliary power source 146 can be inserted into the fluid control system 100 in parallel with the manual pump 108. In other embodiments, the manual pump 108 can be connected to a battery to provide a battery-powered pump. Moreover, in other embodiments, the auxiliary power source 146 can replace the manual pump 108 so that the manual pump 108 is removed from the fluid control system 100.

[0060] refer to Figure 5-10B , other example configurations of a fluid control system 200 (and for a fluid control system) according to an embodiment of the present invention are shown. Similar to the fluid control system 100 described above, the fluid control system 200 can include an energy storage system 202 in communication with an actuator 204. The energy storage system 202 can include a container, such as an accumulator (as further described below), a pump 208, and a motor 210. For example, the fluid control system 200 can be in communication with a valve (e.g., valve 120 in a conduit 122). The valve 120 can be stroked by the actuator 204 to close (or open) the valve 120 and affect the flow of the process fluid through the conduit 122.

[0061] In some examples, the fluid control system 200 can include a thermal volume controller configured as a motor control device 240. In some examples, the thermal volume controller can ensure that the energy storage system 202 is fully charged or otherwise properly filled with the control fluid during a recharging operation. For example, the thermal volume controller can operate a switch (e.g., an electrical switch) based on the fluid level or piston position to activate and deactivate the motor 210 and the pump 208, which fills or charges a container (e.g., a tank or accumulator) with the control fluid.

[0062] Moreover, in some examples, the thermal volume controller can compensate for (i.e., adjust when necessary) pressure changes or fluctuations in the process fluid pipeline 122. Therefore, unlike conventional electro-hydraulic systems, the example thermal volume controllers disclosed herein are able to operate the motor or pump without the need for a pressure switch. Conventional pressure switches may need to be recalibrated or readjusted when the pressure of the process fluid changes or fluctuates in the pipeline. In contrast, the example thermal volume controllers described herein may not require any adjustments because they are able to automatically adjust to compensate for pressure fluctuations of the process fluid in the pipeline. In addition, the example thermal volume controllers disclosed herein can compensate for thermal expansion or pressure changes of the control fluid of the example control fluid power device caused by temperature changes (e.g., day and night temperature changes).

[0063] Figure 5 One example configuration of a fluid control system 200 is shown. In this example, an energy storage system 202 includes an accumulator 206 in communication with a motor control 240 . Figure 5 The motor control device 240 can include a sensor, for example, configured as a switch 242. In the example shown, the switch 242 is located near the bottom of the accumulator 206. The switch 242 can be connected (e.g., threaded) at the wall of the accumulator 206 or connected through the wall of the accumulator 206. As described above with respect to Figure 1-4As described above with respect to the accumulator 106, the accumulator 206 can similarly include a first chamber 244 and a second chamber 246, the first chamber 244 and the second chamber 246 being separated by a barrier (e.g., a piston 248, such as Figure 6 as shown) and the fluids separate.

[0064] Typically, a pump 208 (which can be connected to a motor 210) can draw control fluid from a fluid reservoir 130 and discharge the control fluid into a first chamber 244 of the accumulator 206. The first chamber 244, the pump 208, and the reservoir 130 can form part of a first flow system. A second chamber 246 of the accumulator 206 is configured to be filled with process fluid from the pipeline 122 and is isolated from the first chamber 244 (e.g., by a piston 248). Thus, the second chamber 246 provides a second flow system that is fluidly closed to the first flow system.

[0065] The switch 242 can be configured to send a signal to the motor 210 to turn on the motor 210 and thereby send fluid from the fluid reservoir 130 to the first chamber 244, or to turn off the motor 210 and thereby stop the pump 208 from operating so that fluid does not move from the fluid reservoir 130 to the first chamber 244 through the pump 208. In some examples, the switch 242 can include a sensor that can sense the position of the piston 248 within the accumulator 206 (thus indirectly sensing the control fluid level). For example, when the switch 242 senses that the piston 248 is in a position corresponding to a non-maximum operating volume of the control fluid in the first chamber 244 (e.g., when the switch 242 is not triggered), the switch 242 can cause the motor 210 to operate so as to send fluid to the first chamber 244. Accordingly, when the switch 242 senses that the piston 248 is in a position corresponding to a maximum operating volume of the control fluid in the first chamber 244 (eg, when the switch 242 is triggered), the switch 242 can signal the motor 210 to turn off (or remain off).

[0066] The maximum operating volume of the control fluid in the first chamber 244 can correspond to the maximum volume of the control fluid in the first chamber 244 minus the compensation volume of the first chamber 244. For example, the accumulator 206 can be provided with a maximum operating volume that is large enough to hold a volume of control fluid that can provide enough potential energy to the actuator 204 to stroke the valve 120 to open or close, but also provide additional volume (i.e., the compensation volume) available in the accumulator to allow for appropriate thermal expansion of the control fluid. Thus, in some examples, the size of the compensation volume for a particular accumulator can be flexibly selected by selecting a particular set point for the maximum operating volume (e.g., by arranging the switch 242 to be activated at a more or less advanced position of the piston 248).

[0067] In some examples, the stored potential energy corresponding to the maximum operating volume can be sufficient to stroke the valve 120 multiple times before recharging the accumulator 206 with the control fluid. Therefore, in some examples, the compensation volume can be formed by a gap that can provide thermal compensation within the energy storage system 202 when the control fluid is at the maximum operating volume. In this regard, the maximum operating volume of the control fluid can be less than the maximum volume of the first chamber 244, so that the resulting compensation volume can allow for any expansion (or related changes in properties) of the control fluid without damaging the accumulator 206 or affecting the ability of the accumulator 206 to stimulate the actuator 204 to cause the valve 120 to stroke.

[0068] Typically, the compensation volume can protect the fluid control system 200 from overpressure and can be integrated within the accumulator 206. Thus, in some cases, only a single accumulator (e.g., the accumulator 206 having a thermal volume controller configured as the motor control device 240) may be required in the fluid control system 200. In other words, thermal compensation within the fluid control system 200 can occur in series with the accumulator 206 (e.g., within the accumulator 206), as opposed to the parallel arrangement used in conventional approaches.

[0069] In some embodiments, the fluid control system 200 can also include an exhaust system that is fluidly disposed between the accumulator 206 and the valve 120. The exhaust system can be used, for example, when performing maintenance on the fluid control system 200 to release any excess pressure from the working fluid. The exhaust system can be effectively used when there is a maximum volume of control fluid in the first chamber 244 so that there is a minimum volume of fluid that needs to be exhausted or decompressed in the second chamber 246.

[0070] Figure 6 An example configuration of an accumulator 206 equipped with a thermal volume controller provided as a motor control device 240 is shown. Figure 6As shown, the switch 242 is arranged near one end 250 of the accumulator 206, adjacent to the second chamber 246. In use, when the piston 248 moves from one end 250 of the accumulator 206 to the other end 252 of the accumulator, the switch 242 can control the motor 210 based on the position of the piston 248 (for example, when the piston 248 is closer to the first end 250 and the control fluid is at the maximum operating volume, the motor 210 is turned off, and when the piston 248 is closer to the other end 252 and the control fluid is below the maximum operating volume, the motor 210 is turned on). In some embodiments, the piston 248, the piston head, the piston rod, or other components that are stationary relative to the piston 248 (i.e., components that move with the piston) can include a supplemental switch activator or target 254 that moves relative to the switch 242 to activate or deactivate the motor 210, and thus activate or deactivate the pump 208. In some embodiments, the switch 242 (and the target 254) can be configured as a magnetic sensing switch or other linear distance switch or sensor.

[0071] For example, the supplemental target 254 sensed by the switch 242 can include a ferrous or magnetic material, and the switch 242 can be configured as a proximity switch. Thus, activation or deactivation of the switch 242 can occur without the supplemental target 254 being directly engaged with the switch 242. For example, when the target is in proximity relative to the switch 242 (without directly engaging or contacting the switch 242), the piston 248 can activate or deactivate the motor 210.

[0072] Figure 7 Another example configuration of a fluid control system 200 is shown. Figure 5 The structure shown, Figure 7 The illustrated configuration can include a motor control 240 having a switch 242, but the switch 242 can be used with Figure 5 In particular, the switch 242 can be fixed on a switch rod 256 that is fixed relative to the accumulator 206 and extends into the accumulator 206. The piston 248 can include a target 254 that is fixed relative to the piston rod 262 so that the target 254 moves with the piston 248. Therefore, the arrangement of the switch 242 and the target 254 can sense the relative position of the piston within the accumulator 206. For example, when the switch 242 senses that the piston 248 is in a position corresponding to a non-maximum operating volume of the control fluid, the switch can signal the motor 210 to operate. Accordingly, when the switch 242 senses that the piston 248 is in a position corresponding to a maximum operating control volume of the control fluid in the accumulator 206, the switch 242 can signal the motor 210 to turn off (or remain off).

[0073] Figure 8 It indicated Figure 7An example configuration of an accumulator 206 equipped with a thermal volume controller is provided as a motor control device 240. In the configuration shown, the motor control device 240 includes a switch 242 fixed to a switch rod 256 and a target 254 fixed to a piston rod 262. As shown, the piston rod 262 extends through the first chamber 244 and opposes the piston 248 from the second chamber 246. Thus, the motor control device 240 is able to provide thermal compensation in series with (and integrated within) the accumulator 206 by activating or deactivating the motor so as to start and stop according to the maximum operating volume of the control fluid and a specified compensation volume (e.g., gap) within the accumulator 206 based on the position of the piston 248.

[0074] In some embodiments, the compensation gap may be varied based on various factors of the fluid control system 200 and its environment. For example, these factors may include control fluid type, working fluid type, maximum working fluid pressure, accumulator size (e.g., capacity), valve stroke requirements, ambient temperature, and altitude. Thus, the compensation gap may be adjusted to provide adequate compensation based on one or more internal or external system factors, and may vary in size (e.g., volume) for different configurations. For example, in some configurations, the size of the compensation gap may be designed to compensate for a 100°F temperature change and the associated thermal expansion of the control fluid.

[0075] Fig. 9 Another example configuration of a fluid control system 200 is shown. Fig. 9 The illustrated fluid control system 200 includes an energy storage system 266. The energy storage system 266 includes a container 268 in fluid communication with the pump 208 and the pipeline 122. Thus, the container 268 can be filled against the gas pressure of the process fluid in the pipeline 122. As the control fluid fills the container 268, the potential energy stored in the container 268 increases. When the container 268 is fully filled, the control fluid is at a maximum operating volume.

[0076] The fluid control system 200 can be equipped with a thermal volume controller integrated with the container 268 via a motor control 270. Similar to the thermal volume control described above, the motor control 270 can include a switch 272 to activate and deactivate the motor 210 and the pump 208, which fills the container 268 with control fluid. The motor control 270 can provide a thermal volume controller that can be adjusted to compensate for pressure or volume fluctuations in the control fluid or process fluid within the pipeline 122.

[0077] For example, switch 272 can be configured as a motor stop level switch and can be located near the top 276 of container 268. When the fluid level reaches a predetermined height in the container, a signal can be sent to the motor 210 via switch 272 to shut down. Accordingly, when the fluid level is below a predetermined threshold, the motor 210 can be operated to fill the container 268. In some embodiments, switch 272 can be configured as a fork-type level switch, such as a vibrating fork. In use, for example, when the level switch senses fluid between the arms of the fork, the motor can be shut down. Accordingly, when the level switch does not sense fluid between the arms of the fork, the motor can be turned on.

[0078] The container 268 can also include a secondary switch 274. The secondary switch 274 is optional in the fluid control system 200 and can be configured as a low level switch. The secondary switch 274 can be used to notify a user when the control fluid in the container 268 is low; additionally or alternatively, the secondary switch 274 can be used as a stop to prevent an attempted stroke from the actuator 204 when the control fluid is too low and the container 268 is not filled enough to complete a full valve stroke (or other desired operation). In one example, the secondary switch 274 can be used to confirm the de-energized or depressurized state of the container 268 during a maintenance procedure.

[0079] In some embodiments, the container 268 can also include an internal bladder that fluidically separates the control fluid from the working fluid of the conduit 122. Conversely, in some embodiments, the control fluid may not be separated from the working fluid from the conduit 122. In this regard, the physical location (e.g., height) of the sensor is important to provide a compensating gap within the container 268 to accommodate volume changes (including bubbling interactions between the control fluid and the working fluid).

[0080] Fig. 10A and 10B Example states of container 268 in fluid control system 200 are shown. Fig. 10A 278 is below the sensor threshold measured by switch 272 and motor 210 is active (eg, running) to pump control fluid into container 268. Conversely, Fig. 10B 278 is a condition in which the control fluid is at or above the sensor threshold measured by the switch 272 and the motor 210 is deactivated (eg, not running) such that the control fluid 278 is no longer being pumped into the container 268. Fig. 10B The control fluid 278 is shown at a maximum operating volume (in some examples).

[0081] Furthermore, the state in which the motor 210 is stopped is shown. Fig. 10BA compensation gap 280 (e.g., a compensation volume) within the container 268 is shown. The compensation gap 280 can provide thermal compensation, which, as described above, can compensate for or otherwise adjust for pressure and volume changes or fluctuations in the fluid. The sum of the maximum operating volume of the control fluid and the compensation gap can be the total capacity of the container 268. It should be noted that thermal compensation (via the compensation gap 280) occurs in series with the container 268 (and within the container 268), thereby eliminating the need for additional, external or parallel thermal compensation. Typically, external or parallel thermal compensation can increase cost, maintenance, repair, and complex installation.

[0082] In some embodiments, the devices or systems disclosed herein can be utilized, manufactured, or installed using methods that embody aspects of the present invention. Accordingly, any description of specific features, capabilities, or intended purposes of devices or systems herein will generally include disclosure of methods for using these devices for intended purposes, methods for otherwise achieving these capabilities, methods for manufacturing related components of these devices or systems (or entire devices or systems), and methods for installing disclosed (or otherwise known) components to support these purposes or capabilities. Similarly, unless otherwise specified or limited, the discussion herein of any method of manufacturing or using a particular device or system (including installing the device or system) will inherently include disclosure of the utilization features and enabling capabilities of these devices or systems as embodiments of the present invention.

[0083] Also as used herein, unless otherwise limited or defined, "or" represents a non-exclusive list of components or operations that can exist in any various combinations, rather than an exclusive list of components that can exist only as alternatives to each other. For example, a list of "A, B, or C" represents the following options: A; B; C; A and B; A and C; B and C; and A, B, and C. Accordingly, the term "or" as used herein will only represent exclusive alternatives when preceded by an exclusive term such as "any," "one of," "only one of," or "exactly one of." For example, a list of "one of A, B, or C" indicates the following options: A but not B and C; B but not A and C; and C but not A and B. A list preceded by "one or more" (and variations thereof) and including "or" to separate the listed elements represents the option of one or more of any or all of the listed elements. For example, the phrases "one or more of A, B, or C" and "at least one of A, B, or C" represent the following options: one or more A; one or more B; one or more C; one or more A and one or more B; one or more B and one or more C; one or more A and one or more C; and one or more A, one or more B, and one or more C. Similarly, a list preceded by "plurality" (and variations thereof) and including "or" to separate the listed elements represents the option of multiple instances of any or all of the listed elements. For example, the phrases "plurality of A, B, or C" and "two or more of A, B, or C" represent the following options: A and B; B and C: A and C; and A, B, and C.

[0084] As used herein, unless otherwise defined or limited, directional terminology is used to facilitate discussion with reference to a particular figure or embodiment. For example, references to a downward (or other) direction or a top (or other) position may be used to describe aspects of a particular example or figure, but similar orientations or geometries are not necessarily required in all installations or configurations.

[0085] As also used herein, unless otherwise limited or defined, "substantially parallel" means a direction within ±12 degrees (e.g., within ±6 degrees) of a reference direction, including end values. For a nonlinear path, a path can be considered to be substantially parallel to a reference direction when a straight line between the endpoints of the path is substantially parallel to the reference direction, or when the average derivative of the path in a common reference frame serving as the reference direction is substantially parallel to the reference direction.

[0086] As also used herein, unless otherwise limited or defined, "substantially perpendicular" means a direction within ±12 degrees (e.g., within ±6 degrees) of perpendicular to a reference direction, including end values. For a nonlinear path, a path can be considered substantially perpendicular to a reference direction when a straight line between the endpoints of the path is substantially perpendicular to the reference direction, or when the average derivative of the path in a common reference frame serving as the reference direction is substantially perpendicular to the reference direction.

[0087] As also used herein, unless otherwise limited or defined, "integral" and its derivatives (e.g., "integrally") describe an element that is manufactured as a single piece, without fasteners, adhesives, etc., to secure the separate components together. For example, an element that is stamped, cast, or otherwise molded as a single-piece component from a single piece of sheet metal or using a single die without rivets, screws, or adhesives to hold the separately formed parts together is an integral (and integrally formed) element. In contrast, an element that is formed from multiple parts that are initially formed separately and then connected together is not an integral (or integrally formed) element.

[0088] In addition, unless otherwise specified or limited, the terms "about" and "approximately" used herein with respect to a reference value refer to a change of ±15% or less relative to the reference value, including the end points of the range. Similarly, the term "substantially equal" (etc.) used herein with respect to a reference value refers to a change of less than ±30% relative to the reference value, including the end points. In the case of a designation, "substantially" can particularly represent a change in a numerical direction relative to the reference value. For example, "substantially less than" a reference value (etc.) means a value reduced by 30% or more from the reference value, and "substantially greater than" a reference value (etc.) means a value increased by 30% or more from the reference value.

[0089] As also used herein, unless otherwise limited or specified, "substantially the same" refers to two or more components or systems that are manufactured or used according to the same processes and specifications, wherein the variations between the components or systems are within the limits of acceptable tolerances for the relevant processes and specifications. For example, two components can be considered substantially the same when the components are manufactured according to the same standardized manufacturing steps, using the same materials, and within the same acceptable dimensional tolerances (e.g., as specified for a particular process or product).

[0090] The foregoing description of the disclosed embodiments is provided to enable those skilled in the art to make or use the present invention. In view of the benefits of the present invention, various variations of these embodiments will be apparent to those skilled in the art, and the principles identified herein can be applied to other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but should be based on the widest range consistent with the principles and novel features disclosed herein.

Claims

1. A fluid control system (100; 200), comprising: Actuator (104; 204), the actuator being configured to move the valve (120) between an open position and a closed position; as well as An energy storage system (102; 202), the energy storage system and the actuator (104; 204) is fluidly connected to drive the actuator (104; 204), the energy storage system (102; 202) comprises: a single accumulator (106; 206) having a first chamber (138; 244) in fluid communication with the actuator (104; 204) and a second chamber (140; 246) in fluid communication with the conduit (122) for receiving pressurized fluid from the conduit (122); and a pump (108; 208) arranged to pump hydraulic fluid into a first chamber (138; 244) of the single accumulator (106; 206) in order to charge the single accumulator against the pressure of the pressurized fluid in the second chamber (140; 246), The energy storage system (102; 202) determines: a fully charged state in which the first chamber (138; 244) of the single accumulator (106; 206) comprises a maximum operating volume of hydraulic fluid and the second chamber (140; 246) comprises a minimum operating volume of pressurized fluid; and A fully discharged state in which a first chamber (138; 244) of a single accumulator (106; 206) includes a minimum operating volume of hydraulic fluid and a second chamber (140; 246) includes a maximum operating volume of pressurized fluid.

2. The fluid control system according to claim 1, wherein: a pump (108; 208) in fluid communication with the actuator (104; 204) and the fluid reservoir (130), and Operation of the pump (108; 208) places the energy storage system (102; 202) in a charged state, in which the pump (108; 208) pumps hydraulic fluid from the fluid reservoir (130) into a first chamber (138; 244) of a single accumulator (106; 206), optionally or preferably, the pump (108; 208) is a manual pump that can be manually operated without electricity.

3. The fluid control system according to claim 1 or 2, wherein: The energy storage system (102; 202) determines a discharge state in which hydraulic fluid flows from a first chamber (138; 244) of a single accumulator (106; 206) to the actuator and pressurized fluid flows from a conduit (122) into a second chamber (140; 246) of the single accumulator (106; 206).

4. A fluid control system according to any preceding claim, further comprising: A directional control valve for directing hydraulic fluid from a first chamber (138; 244) of a single accumulator (106; 206) to an actuator (104; 204) so ​​as to move the actuator in a first direction, and also for directing hydraulic fluid movement from the first chamber (138; 244) of the single accumulator to the actuator so as to move the actuator in a second direction, optionally or preferably, moving the actuator (104; 204) in the first direction will open the valve (120), and moving the actuator (104; 204) in the second direction will close the valve (120).

5. The fluid control system of claim 4, wherein: (i) moving the actuator (104; 204) in a first direction to fully close the valve (120) and (ii) moving the actuator (104; 204) in a second direction to open the valve (120) from a closed state each provide a corresponding valve event, and A single accumulator (106; 206) is configured to supply flow for less than two valve events before reaching a fully discharged state.

6. The fluid control system according to claim 4 or 5, wherein: (i) moving the actuator (104; 204) in a first direction to fully close the valve (120) and (ii) moving the actuator (104; 204) in a second direction to open the valve (120) from a closed state each provide a corresponding valve event, and A single accumulator (106; 206) is configured to provide at least three valve events before reaching a fully discharged state.

7. A fluid control system according to any preceding claim, wherein: The hydraulic fluid is contained in a first flow system and the pressurized fluid is contained in a second flow system that is fluidly closed to the first flow system.

8. The fluid control system of claim 1, further comprising: A quick connect system (148) configured to selectively connect a portable pump (146) in parallel with the pump (108) so that the portable pump is arranged to pump hydraulic fluid into a first chamber (138; 244) of a single accumulator (106; 206) to charge the single accumulator against the pressure of pressurized fluid in a second chamber (140; 246).

9. A fluid control system according to any preceding claim, wherein: An energy storage system (102; 202) allows a single accumulator (106; 206) to transition from a fully charged state to a fully discharged state without operating a pump (108; 208).

10. An energy storage system (102; 202) for driving an actuator (104; 204), the actuator being arranged to move a valve (120) between an open position and a closed position so as to control the flow of a process fluid through a portion of a pipeline (122), the energy storage system (102; 202) comprising: a container (106; 206; 268) defining an interior chamber (138; 244; 268) in fluid communication with the actuator (104; 204) and a pump (108; 208) configured to fill the container (106; 206; 268) with a control fluid against pressure exerted by a process fluid; and A sensor (242; 272) is configured to sense a fluid level of a control fluid within the container (106; 206; 268) and to send a signal indicating whether the control fluid is at a maximum operating volume, the maximum operating volume being less than the total volume of the internal chamber of the container (106; 206; 268).

11. The energy storage system of claim 10, wherein: The container (106; 206; 268) is not arranged to operate in parallel with the accumulator.

12. The energy storage system according to claim 10 or 11, further comprising: A manual pump (108; 208) configured to pump hydraulic fluid to a container (106; 206； 268) in order to fill the container against the pressure of the process fluid, The operation of the manual pump (108; 208) causes the container to be in a filling state, in which the manual pump (108; 208) pumps hydraulic fluid from the fluid reservoir (130) into the container (106; 206; 268), and optionally or preferably, the container (106; 206; 268) determines a discharge state, in which the hydraulic fluid flows from the container to the actuator (104; 204), and the pressurized process fluid flows from the pipeline (122) into the container (106; 206; 268).

13. An energy storage system according to any one of claims 10 to 12, wherein: The process fluid is fluidically separated from the hydraulic fluid, optionally or preferably the container (106; 206; 268) is a single accumulator.

14. A method of actuating a valve (120) of a pipeline (122) for processing a fluid, the method comprising: charging the accumulator (106; 206), wherein charging the accumulator comprises manually pumping a control fluid from a fluid reservoir (130) to charge a first chamber (138; 244) of the accumulator (106; 206) with the control fluid, The control fluid is caused to flow out of the first chamber (138; 244) by being powered by the pressure of the process fluid in the conduit (122), thereby discharging the accumulator (106; 206) to drive the actuator (104; 204) of the valve (120).

15. The method according to claim 14, wherein: Discharging the accumulator (106; 206) includes sending a signal to control fluid flow from the first chamber (138; 244) of the accumulator to the actuator (104; 204), and sending process fluid from the conduit (122) to the second chamber (140; 246) of the accumulator (106; 206), and Discharging the accumulator (106; 206) does not include operating a pump (108; 208) in fluid communication with the accumulator (106; 206).

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