Gas Pressure Regulator With Dual Control Heads and Fail-Open Backup
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Solution Overview
Problem
Existing pressure regulators for gas distribution systems face limitations in precision and response time, with direct acting regulators offering quick response but limited precision and requiring on-site adjustments, while pilot device regulators provide precise control but have longer response times and reliability issues, especially in 'fail open' scenarios and remote management.
Innovation Solution
A pressure regulator design combining pilot-controlled and direct-controlled mechanisms, with a dual control head system where one head is pilot-controlled and the other is directly controlled, allowing for quick response and reliable operation even in pilot device failures, and incorporating a 'fail open' safety system with remote pressure adjustment capabilities through a flexible pilot device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a direct acting pressure regulator is used, then the response time is quick, but the regulation precision is limited
Solution Approach 1:
The regulator is divided into two independent control heads: a direct-acting control head for quick response and a pilot control head for precise regulation. Each control head operates independently but can control the same shutter, allowing the system to leverage the strengths of both mechanisms without compromise.
2Measurement precision
If a pilot device regulator is used, then the regulation precision is improved, but the response time increases
Solution Approach 1:
The regulator is divided into two independent control heads: a direct-acting control head for quick response and a pilot control head for precise regulation. Each control head operates independently but can control the same shutter, allowing the system to leverage the strengths of both mechanisms without compromise.
3Measurement precision
If a pilot device regulator is used, then the regulation precision is improved, but the reliability decreases in fail open scenarios
Solution Approach 1:
The system incorporates a fail-open mechanism where the direct-acting control head is spring-loaded to automatically open the shutter if the pilot control head fails. This pre-configured safety mechanism ensures that gas flow is restored in case of pilot device failure, preventing hazardous pressure buildup downstream.
Solution Approach 2:
The direct-acting control head serves as an intermediary backup system that can take over control of the shutter if the pilot control head becomes inoperative. This dual-control arrangement provides redundancy and ensures continuous safe operation of the gas distribution system.
4Speed
If a direct acting pressure regulator is used, then the response time is quick, but the setting adjustment requires on-site manual operation
Solution Approach 1:
The pilot control head acts as an intermediary device that receives remote control signals and translates them into pressure adjustments. This allows the setting pressure to be modified remotely without requiring on-site manual intervention, while the direct-acting control head maintains the quick response capability.
5Measurement precision
If a pilot device regulator is used, then the regulation precision is improved, but the device complexity increases
Solution Approach 1:
The regulator is divided into two independent control heads: a direct-acting control head for quick response and a pilot control head for precise regulation. Each control head operates independently but can control the same shutter, allowing the system to leverage the strengths of both mechanisms without compromise.
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 solution achieves reliable and precise pressure regulation with quick response times, enabling remote management and easy adaptation to various applications, ensuring system reliability and safety with a 'fail open' capability.
Implementation Method 1
a movable wall connected to the shutter and associated with a counter-thrust spring. As long as the pressure in the motorization chamber is balanced with the force of the spring, the movable wall does not move.
Implementation Method 2
the delay is only the delay related to the mechanical inertia of the components of the regulator and to the time necessary for the propagation of the pressure perturbation from the outflow duct to the shutter chamber
Data Source
AI summary
A pressure regulator for gas distribution systems includes: a connection body for connection between an upstream pipe and a downstream pipe, the following elements being defined inside the connection body: an inlet duct an outlet duct, a high-pressure chamber connected to the inlet duct, a low-pressure chamber connected to the outlet duct, a passage opening between the high-pressure chamber and the low-pressure chamber, a movable shutter designed to obstruct the passage opening, components for moving the movable shutter in a controlled manner. The components for moving the movable shutter in a controlled manner include: a first main control head fixed to the connection body and configured to operate the movable shutter through a first control rod, a second auxiliary control head configured to operate the movable shutter through a second control rod fixed to the same movable shutter.