Acetylene Safety Valve Monolithic Design
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Solution Overview
Problem
Existing safety devices for gas supply systems, particularly acetylene systems, face challenges in reliability and durability due to unpredictable pressure fluctuations and the risk of acetylene decomposition, leading to potential explosions and environmental hazards.
Innovation Solution
A compact safety device integrating a quick-action closing device and a pressure-limiting device within a single monolithic valve housing, featuring a safety valve that automatically shuts off the gas supply when pressure limits are exceeded, eliminating the need for separate relief valves and ensuring reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate relief valves and quick-acting devices are used in acetylene supply systems, then safety functions are provided, but device complexity increases and reliability decreases due to multiple failure points
Solution Approach 1:
The patent combines multiple safety functions (pressure relief, quick-closing, and shutdown control) into a single integrated safety device. The valve body houses both the pressure relief valve and the quick-closing valve with their respective actuating mechanisms, eliminating the need for separate components and reducing the number of potential failure points while maintaining comprehensive safety coverage.
Solution Approach 2:
The integrated safety device performs multiple safety functions simultaneously: it provides pressure relief through the pressure relief valve, rapid shutdown through the quick-closing valve, and system-wide shutdown through the shutdown valve. This multi-functional design consolidates what would traditionally require multiple separate devices into one universal safety component.
2Stress or pressure
If acetylene is vented to atmosphere through relief valves, then pressure relief is achieved, but environmental pollution and safety hazards increase
Solution Approach 1:
The patent converts the potentially harmful discharge of acetylene to atmosphere into a controlled shutdown event. When the pressure relief valve opens due to overpressure, it simultaneously triggers the quick-closing valve and shutdown valve to close, stopping the gas flow. This transforms what would be continuous harmful discharge into a brief, controlled pressure equalization event followed by complete system isolation.
Solution Approach 2:
The pressure relief valve and quick-closing valve are fluidically connected such that when the pressure relief valve opens in response to overpressure, it automatically triggers the quick-closing valve to close. This feedback mechanism ensures that the moment pressure relief begins, the gas supply is immediately cut off, preventing further discharge to atmosphere and eliminating the need for continuous venting.
3Reliability
If quick-acting valves are destroyed during acetylene decomposition, then safety function is performed, but operational continuity is interrupted requiring replacement
Solution Approach 1:
The patent incorporates a robust valve body design that is specifically engineered to withstand the extreme conditions of acetylene decomposition, including pressures exceeding 1000 bar. The valve body acts as a protective structure that absorbs and withstands the decomposition forces, shielding the internal valve components from direct damage and allowing the system to maintain operational integrity after a safety event.
4Reliability
If manual or automatic quick-acting devices are installed upstream, then acetylene decomposition spread is stopped, but the devices must withstand detonation pressures exceeding 1000 bar
Solution Approach 1:
The patent merges the containment function with the shutdown function in a single integrated design. The valve body and valve components serve dual purposes: they contain the decomposition pressure and simultaneously execute the shutdown action. This integration eliminates the need for separate containment structures and reduces the overall complexity of withstanding extreme pressures.
Solution Approach 2:
The valve body is designed with inherent strength and structural features that allow it to withstand detonation pressures exceeding 1000 bar. The design incorporates pressure distribution features and robust material selection that prepare the structure to absorb and dissipate extreme pressures without failure, providing beforehand cushioning against the expected mechanical stresses of acetylene decomposition.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The integrated solution provides enhanced operational reliability and safety by automatically shutting off the gas supply when pressure limits are reached, preventing accidents and reducing the risk of acetylene decomposition-related hazards, while also simplifying the design and maintenance of the safety device.
Implementation Method 1
the pressure relief valve (4) opens, so that acetylene gas can escape from the pressure relief valve inlet (15) at the admission pressure to the pressure relief valve outlet (47) at the relief pressure
Implementation Method 2
the control valve (3) opens, so that acetylene gas can escape from the control valve inlet (32) at the back pressure to the control valve outlet (39) at the outlet pressure
Implementation Method 3
the safety valve piston (10) divides the safety valve chamber into a front pressure chamber (11) and a rear pressure chamber (12)... the safety valve piston (10) has a larger effective cross section in relation to the gas pressure in the rear pressure chamber (12) than in relation to the gas pressure in the front pressure chamber (11)
Implementation Method 4
a wave spring (13) rests on the upper side of the circumferential area (19) and holds the piston (10) in the open position during normal operation
Implementation Method 5
In the closed position, the safety valve piston (10) rests against a sealing ring (118) which is let into a circumferential groove in the inner wall of the gas inlet (15)
Implementation Method 6
Acetylene (C 2 H 2 ) is known to be highly flammable and decomposes into its elements at high temperature or high pressure, generating heat. Under certain circumstances, the decomposition can be detonative
Data Source
Figure 1
Figure 2~4
Figure 5
AI summary
Relevant regulations in the field of gas supply specify various safety devices for installation in a gas supply system, particularly for an acetylene supply system. To provide such a safety device, characterized by a compact design and high operational reliability, the invention proposes that a pressure relief valve (4; 104) of a quick-closing device, a control valve (3; 103) of a pressure limiting device, and a safety valve (2; 102) be incorporated in a valve body (1). The safety valve (2; 102) is fluidically connected to the pressure relief valve (4; 104) and the control valve (3; 103) and closes either when the pressure relief valve (4; 104) opens due to an upstream pressure exceeding a pre-pressure limit value, or when the control valve (3; 103) opens due to a downstream pressure exceeding a pre-pressure limit value.