Ball Valve Pulse Control for Lower Breakaway Torque
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Solution Overview
Problem
Ball valves experience sticking issues due to prolonged use, leading to increased resistance and breakaway torque requirements, which can exceed the capabilities of electronic actuators, especially when handling certain fluids that cause calcifications, resulting in inefficiencies and potential failure to rotate.
Innovation Solution
Applying controlled electric pulses to the ball valve actuator to slightly rotate the ball, reducing sticking by maintaining lower breakaway torque requirements and preventing fluid stagnation, which can be generated locally or remotely and tailored for specific valve configurations and fluid types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ball valves are used for prolonged periods, then fluid control function is maintained, but resistance and breakaway torque increase due to sticking
Solution Approach 1:
The patent applies periodic pulsing action to the ball valve mechanism, where pulses are delivered at predetermined intervals to prevent sticking. The controller activates the ball valve in a pulsing manner rather than continuous operation, which reduces resistance buildup while maintaining fluid control reliability over prolonged periods.
Solution Approach 2:
The system performs preliminary action by delivering pulses before complete stagnation or severe sticking occurs. The controller monitors operation duration and applies preventive pulsing at predetermined intervals to maintain low breakaway torque requirements before resistance becomes excessive.
2Extent of automation
If electronic actuators are used to control ball valves, then automated control is achieved, but torque limitations prevent operation when calcifications occur
Solution Approach 1:
The patent implements dynamic control by adjusting the pulsing parameters based on operational conditions. The controller modifies pulse duration, frequency, and intensity adaptively to overcome calcification-induced sticking while remaining within the electronic actuator's torque capabilities, thus maintaining automated control reliability.
Solution Approach 2:
The system changes operational parameters by varying pulse characteristics (duration, frequency, intensity) to overcome torque limitations. When calcifications cause increased resistance, the controller adjusts pulse parameters to deliver sufficient force within actuator capabilities, maintaining automated operation capability.
3Productivity
If ball valves operate continuously, then fluid flow control is maintained, but fluid stagnation and bacterial growth occur
Solution Approach 1:
The patent applies periodic pulsing to create flow disturbances that prevent fluid stagnation. By activating the ball valve in pulses at predetermined intervals, the system maintains productivity through continued flow control while disrupting conditions that lead to bacterial growth and fluid stagnation.
Solution Approach 2:
The system maintains continuous useful action for fluid flow control while incorporating periodic pulsing. The pulsing occurs during normal operation rather than interrupting service, ensuring continuous productivity while preventing harmful stagnation effects through ongoing flow disturbance.
Data Source
AI summary
Aspects of the disclosure relate to providing a pulse control to a ball valve to reduce the amount of torque required to adjust the position of the ball valve. In an aspect, the technology relates to a method for reducing resistance of a ball valve. The method includes generating a pulse having a duration and a polarity; providing the pulse to an actuator configured to rotate a ball of the ball valve; and rotating, by the actuator, the ball of the ball valve by an amount based on the duration of the pulse and a direction based on the polarity of the pulse, wherein the ball valve does not change state after rotation of the ball.