Back-Pressure Regulator Pilots With Adjustable Opening and Closing Setpoints
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Solution Overview
Problem
Current fluid distribution systems with back-pressure regulators or relief valves are limited by their single setpoint design, which does not allow for adjustable operation, making it difficult to manage pressure variations effectively in applications like biomethane production where different pressure setpoints are required for optimal operation.
Innovation Solution
A control system comprising a pressure regulator, a first pilot, and a second pilot, where the first pilot is configured to open and close based on different setpoints, allowing the system to operate in multiple modes to manage fluid pressure effectively, including automatic reset and adjustable deadband functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single setpoint back-pressure regulator is used, then the device structure is simple, but the system cannot adapt to different pressure requirements in biomethane production
Solution Approach 1:
The back-pressure regulator is divided into multiple independent pilot devices, each with its own setpoint. The first pilot device controls opening at a first setpoint, while the second pilot device controls closing at a second setpoint. This segmentation allows the system to adapt to different pressure requirements without creating a completely new regulator design.
Solution Approach 2:
The patent implements nesting by placing multiple pilot devices within the actuator assembly of a single back-pressure regulator. The first and second pilot devices are nested within the same regulator body, allowing one regulator to perform multiple pressure control functions. This resolves the contradiction by providing adaptability through multiple setpoints while maintaining a relatively compact structure.
2Measurement precision
If a back-pressure regulator opens and closes at the same setpoint, then the control precision is high, but the system cannot maintain pressure within a desired range for optimal biomethane production
Solution Approach 1:
The patent applies asymmetry by setting different pressure thresholds for opening and closing operations. The first setpoint for opening is higher than the second setpoint for closing, creating an asymmetric control pattern. This allows the system to maintain pressure within a desired range (between the two setpoints) rather than toggling at a single threshold, optimizing biomethane production while maintaining precise control through distinct setpoint values.
3Reliability
If a slam-shut device is used for over-pressure protection, then the safety is improved, but the device requires manual reset which reduces automation
Solution Approach 1:
The back-pressure regulator with adjustable deadband implements self-service by automatically resetting after pressure normalization. When the downstream pressure returns to the normal operating range after triggering the slam-shut function, the regulator automatically reopens without requiring manual intervention. This maintains reliable over-pressure protection while achieving full automation, eliminating the need for manual reset operations.
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 system enables efficient management of fluid pressure by allowing the back-pressure regulator or relief valve to open at one setpoint and close at another, optimizing biomethane production and ensuring automatic reset without manual intervention, enhancing the safety and efficiency of fluid distribution systems.
Implementation Method 1
a diaphragm assembly disposed within the cavity and dividing the cavity into a first chamber in fluid communication with the fluid outlet and a second chamber
Data Source
AI summary
A control system having a pressure regulator, first pilot, and second pilot. The pressure regulator has a fluid inlet, fluid outlet, and actuator assembly with a cavity divided into a first chamber in fluid communication with the fluid outlet and a second chamber. The first pilot has a first setpoint and the second pilot has a second setpoint, less than the first setpoint. The first and second pilots fluidly couple the second chamber to the fluid outlet and isolate the second chamber from the fluid inlet in a first mode of operation, isolate the second chamber from the fluid outlet and fluid inlet in a second mode of operation, and fluidly couple the second chamber to the fluid inlet in a third mode of operation.