Dual Shutter Gas Pressure Regulator for Sealing Erosion
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Solution Overview
Problem
Natural gas pressure regulators in distribution networks face issues with sealing member erosion and impurity accumulation due to high gas speed and thermal shocks, leading to increased downstream pressure and the need for frequent checks or oversized components, which elevate installation and operating costs.
Innovation Solution
A pressure adjusting system with two shutter mechanisms in series, where the primary shutter manages pressure drop and the secondary shutter ensures constant duct closure, reducing deterioration and maintaining pressure stability by controlling the degree of opening based on pilot pressure differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single shutter is used to control gas pressure, then the pressure can be adjusted, but the sealing members suffer from erosion and impurity accumulation due to high gas speed and thermal shocks
Solution Approach 1:
The single shutter is divided into two separate shutters (first shutter and second shutter) that operate independently. The first shutter handles the main pressure reduction while the second shutter manages the final pressure adjustment and sealing. This segmentation distributes the harmful effects of high gas speed and thermal shocks across two components, reducing the erosion and impurity accumulation on each individual sealing member.
Solution Approach 2:
The second shutter acts as an intermediary between the first shutter and the downstream system. It provides a buffer that protects the sealing members from direct exposure to the harshest conditions of high-velocity gas flow and thermal shocks, thereby extending their service life and reliability.
2Speed
If the shutter closes quickly after flow interruption, then pressure control is responsive, but the maximum downstream pressure increases due to delay between flow interruption and shutter closure
Solution Approach 1:
The system is designed so that the first shutter closes first upon flow interruption, creating a preliminary barrier that prevents immediate pressure surge. Then the second shutter closes subsequently, providing a staged closure sequence that manages the pressure transition more effectively and reduces the peak downstream pressure compared to a single-shutter system.
3Stress or pressure
If the cross section is reduced to control pressure, then pressure drop is achieved, but gas speed increases causing erosion and impurity accumulation
Solution Approach 1:
The pressure drop function is segmented between two shutters with different cross-sectional areas. The first shutter has a smaller cross section that creates the main pressure drop, while the second shutter has a larger cross section that allows gas flow at lower velocity. This segmentation enables the system to achieve the required pressure drop while minimizing the gas speed and associated erosion in the critical sealing areas.
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
This configuration prolongs the maintenance of constant downstream pressure, reduces the need for frequent checks, and avoids the necessity for safety devices and oversized components, thereby lowering operational costs and extending the system's operational lifespan.
Implementation Method 1
the change in temperature caused by the gas pressure drop between the two sides of the shutter as a consequence of the known Joule-Thompson effect
Data Source
AI summary
A system for adjusting pressure of a gas includes: a first shutter unit for causing a pressure drop in the gas, from a supply pressure to a delivery pressure; a pilot unit for providing a pilot pressure depending on the difference between the delivery pressure and a predefined setting pressure; a first drive unit operated by the pilot pressure to reduce the opening of the first shutter unit when the delivery pressure exceeds the setting pressure, and vice versa; a second shutter unit in series with the first shutter unit can assume a closed configuration; a second drive unit operated by the pilot pressure to reduce the opening of the second shutter unit when the delivery pressure exceeds the setting pressure, and vice versa. When the first shutter unit is open the opening of the second shutter unit causes a pressure drop smaller than the pressure drop by the first shutter unit.