Dual-Stage Fluid Regulator for Pressure Spike Control
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Solution Overview
Problem
Traditional fluid regulators suffer from issues such as large gas releases, false tripping of over-pressure shut-off devices, and increased greenhouse gas emissions due to environmental conditions, leading to inefficiencies and maintenance challenges.
Innovation Solution
A fluid regulator assembly with a dual-control mechanism system, featuring a first regulator that reduces inlet pressure to an intermediate pressure and a second regulator that further reduces this pressure to a safe outlet pressure, incorporating a control element that adjusts based on inlet pressure thresholds to prevent excessive pressure spikes and eliminate the need for over-pressure shut-off devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a full capacity relief valve is used as a safety feature, then protection against fluid regulator failure is provided, but a large amount of gas is released into the environment causing explosive hazards and greenhouse gas emissions
Solution Approach 1:
The patent changes the parameter of relief valve activation pressure, allowing it to be set higher than traditional designs. This enables the regulator to maintain safe operation at higher pressures without triggering full capacity gas release, thus improving safety while reducing harmful emissions.
Solution Approach 2:
The patent introduces an intermediate pressure sensing mechanism that monitors system pressure and triggers controlled relief actions before dangerous pressure buildup occurs. This intermediary control system prevents the need for full capacity relief valve opening, reducing gas release while maintaining safety.
2Device complexity
If traditional single-stage pressure reduction is used, then simplicity is maintained, but pressure control precision deteriorates under varying inlet conditions
Solution Approach 1:
The patent divides the pressure reduction process into two stages: a primary regulation stage for normal operation and a secondary high-pressure relief stage for abnormal conditions. This segmentation allows precise control under normal conditions while providing robust protection during pressure spikes, without significantly increasing overall device complexity.
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 design minimizes greenhouse gas emissions, reduces false tripping, and ensures safety by allowing higher relief valve settings, protecting consumers from pressure spikes and eliminating the need for OPSO devices, thus enhancing operational efficiency and safety.
Implementation Method 1
a diaphragm configured to control the plug responsive to a control pressure differential across the diaphragm
Data Source
AI summary
A fluid regulator assembly for a fluid, such as a gas, includes a housing and a regulator. The housing includes an inlet, an outlet, and a chamber. The regulator is coupled to the housing and includes a control assembly with a plug, a diaphragm, and a control element. The plug is movable relative to the outlet for controlling a flow of fluid through the housing, and the diaphragm controls the plug responsive to a control pressure acting on the diaphragm. The control element is positionable between a first position and a second position for controlling the control pressure acting on the diaphragm, where, in the first position, the control pressure is an outlet pressure downstream from the outlet, and in the second position, the control pressure is at least an inlet pressure upstream from the outlet.