Dual-Pilot Pressure Regulator for Adjustable Deadband Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current fluid distribution systems lack the ability to adjust the operating setpoints of back-pressure regulators and relief valves, which limits their functionality in applications requiring different pressure management strategies, such as biomethane production, where the valve needs to open at one setpoint and close at another.
Innovation Solution
A control system comprising a first pressure regulator, a downstream fluid control device, and two pilots configured to operate in different modes based on setpoints, allowing the pressure regulator to open and close at distinct pressures, enabling adjustable deadband operation for over and under pressure protection and automatic reset without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a typical back-pressure regulator or relief valve is used with a single setpoint, then the device can maintain pressure below a predetermined value, but it cannot open at one setpoint and close at a different setpoint
Solution Approach 1:
The back-pressure regulator is segmented into two distinct pressure-sensing mechanisms: a first pressure-sensing mechanism that controls valve opening at a first setpoint, and a second pressure-sensing mechanism that controls valve closing at a second setpoint. This segmentation allows independent control of opening and closing pressures, enabling the valve to maintain different setpoints for opening and closing operations.
Solution Approach 2:
The patent implements a nested structure where the first and second pressure-sensing mechanisms are integrated within a single regulator body. The first pressure-sensing mechanism operates at a higher pressure level while the second mechanism operates at a lower pressure level, with both mechanisms nested within the same device housing and sharing common structural elements.
2Reliability
If a slam-shut device is used for overpressure protection, then fluid flow can be cut off when pressure exceeds limits, but manual reset is required to reopen the device
Solution Approach 1:
The regulator incorporates automatic reset functionality through its dual pressure-sensing mechanism. When the downstream pressure drops below the second setpoint after an overpressure event, the second pressure-sensing mechanism automatically triggers the valve to reopen without requiring manual intervention. The system serves itself by using the pressure differential to automatically reset the valve position.
Solution Approach 2:
The patent implements feedback control where the second pressure-sensing mechanism continuously monitors downstream pressure and provides feedback to the valve control system. When pressure falls below the second setpoint, the feedback signal automatically triggers valve reopening, creating a closed-loop control system that responds dynamically to pressure conditions.
3Reliability
If pressure regulators are used to maintain predetermined pressure levels, then delivered gas meets facility requirements, but the system cannot adapt to varying pressure demands in different applications
Solution Approach 1:
The patent enables parameter changes by allowing independent adjustment of the first setpoint (opening pressure) and the second setpoint (closing pressure). This dual-setpoint capability allows the regulator to adapt to different application requirements, such as biomethane production where specific pressure differentials are needed for optimal performance, while maintaining reliable pressure control through the same device.
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 provides enhanced pressure management by allowing adjustable setpoints for opening and closing, improving safety and efficiency by automatically resetting and preventing fluid flow at predetermined pressure levels, thus addressing the limitations of traditional systems.
Implementation Method 1
When the downstream pressure is at a normal operating value, the slam-shut device remains open. When downstream pressure varies beyond its set limits, the slam-shut device closes
Implementation Method 2
a spring assembly positioned in the first chamber and configured to urge the valve plug toward the closed position
Data Source
AI summary
A control system having a first pressure regulator, a downstream fluid control device, first pilot, and second pilot. The first pressure regulator has a fluid inlet, fluid outlet, and actuator assembly with a cavity divided into a first chamber and a second chamber. The downstream fluid control device has a second fluid inlet and a second fluid outlet. 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 second fluid outlet in a first mode of operation, isolate the second chamber from the second fluid outlet in a second mode of operation, and fluidly couple the second chamber to the fluid inlet in a third mode of operation.