Dual-Stage Fluid Regulator for Overpressure Stability
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Solution Overview
Problem
Traditional fluid regulators face issues such as large gas emissions and false tripping due to overpressure shut-off devices, which are inconvenient and costly, and fail to effectively manage pressure spikes and environmental conditions.
Innovation Solution
A fluid regulator assembly with dual control mechanisms that include a first regulator reducing inlet pressure to an intermediate pressure and a second regulator reducing intermediate pressure to an outlet pressure, featuring a control element that adjusts based on inlet or outlet pressure thresholds to prevent false tripping and minimize emissions.
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 creating explosive mixtures and greenhouse gas emissions
Solution Approach 1:
The patent changes the pressure parameter at which the relief valve operates. By setting the relief valve to a higher pressure setting, the system maintains safety protection while reducing the frequency and volume of gas releases, thereby minimizing greenhouse gas emissions and explosive hazards
2Reliability
If an over pressure shut-off (OPSO) device is used, then protection against overpressure is provided, but false tripping occurs due to high flow rates, pressure spikes, and environmental conditions
Solution Approach 1:
The patent introduces a second regulator as an intermediary component between the first regulator and the OPSO device. This second regulator acts as a buffer that absorbs pressure spikes and stabilizes the pressure signal, preventing false tripping of the OPSO device while maintaining overpressure protection
Solution Approach 2:
The patent segments the pressure regulation function into two separate regulators: a first regulator that provides primary pressure reduction and a second regulator that provides fine-tuned pressure control and filtering. This segmentation allows each regulator to operate within optimal parameters, reducing the likelihood of false tripping
3Object-generated harmful factors
If the relief valve setting is lowered to minimize emissions, then greenhouse gas emissions are reduced, but the regulator may trip more frequently under normal operating conditions
Solution Approach 1:
The patent changes the relief valve pressure setting to a higher value, which reduces the frequency of gas releases and minimizes greenhouse gas emissions. The introduction of the second regulator ensures that this higher setting does not cause excessive tripping by providing an additional layer of pressure stabilization
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 dual control mechanism minimizes greenhouse gas emissions and reduces false tripping by allowing higher relief settings, providing robust pressure management and protection against sudden pressure changes.
Implementation Method 1
a diaphragm operably coupled to the plug and configured to control the plug responsive to a control pressure acting on the diaphragm
Data Source
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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.