Compressed Gas Regulator Flow Restriction for Outlet Overpressure
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Solution Overview
Problem
Existing gas regulators lack reliable security measures to prevent excessive outlet pressure, particularly when the pressure reducer is stuck in an open position, and often require electric command signals which may not be available in all end-user facilities.
Innovation Solution
A gas regulator design featuring a fixed flow restriction upstream of the shut-off device and a pressure relief device downstream, with a burst disk and non-return valve, ensuring the pressure at the outlet does not exceed a maximum value without moving parts or electric commands, utilizing a nozzle and filter element for robustness and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pressure relief device is added to protect against outlet overpressure, then safety is improved, but device complexity increases
Solution Approach 1:
The flow restriction is integrated into the gas passage upstream of the shut-off device, merging the pressure limiting function with the existing gas flow path. This combination approach adds safety functionality without requiring a completely separate complex subsystem, thereby improving outlet pressure safety while minimizing the increase in device complexity.
Solution Approach 2:
The flow restriction acts as an intermediary element between the inlet and the pressure reducer, providing passive pressure limitation through its restricted cross-section. This intermediary component enables pressure control without requiring active control systems or complex mechanisms, resolving the contradiction between safety and complexity.
2Reliability
If electrically operable flow limiting valves are used to limit gas flow, then safety is improved, but ease of operation deteriorates due to requirement of command signals
Solution Approach 1:
The flow restriction provides passive, automatic flow limitation through its fixed restricted cross-section in the gas passage. The system serves itself by using the inherent pressure differential and flow dynamics to limit gas flow without requiring external command signals, electrical power, or complex control systems, thereby maintaining safety while ensuring ease of operation.
Solution Approach 2:
The patent replaces electrically operable valves with a passive flow restriction that uses fluid dynamics principles. This substitution eliminates the need for electrical commands and complex actuation mechanisms, achieving safety through simple mechanical/fluid principles that require no external control signals.
3Device complexity
If the pressure relief device acts solely on the external sense line, then device complexity is reduced, but reliability deteriorates as outlet pressure rises without control if piston gets stuck
Solution Approach 1:
The pressure control system is segmented into two independent protective mechanisms: the flow restriction upstream that limits maximum pressure through restricted flow, and the pressure relief device downstream that provides additional protection. This segmentation ensures that if one mechanism fails (e.g., piston stuck), the other continues to provide pressure control, thereby improving reliability while maintaining relatively simple device complexity.
Solution Approach 2:
The flow restriction provides beforehand cushioning by limiting the maximum pressure that can reach the pressure reducer inlet. This pre-established pressure limit acts as a safety buffer that protects against outlet overpressure even if the pressure relief device or piston fails, improving reliability without significantly increasing 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
The regulator effectively maintains outlet pressure within safe limits even if the pressure reducer is blocked, providing reliable security without electric signals, ensuring the pressure at the gas outlet remains controlled and secure.
Implementation Method 1
a flow restriction in the gas passage upstream of the shut-off device, dimensioned for reducing the gas pressure at the gas outlet under a maximum pressure value when the pressure relief device is opened
Implementation Method 2
the pressure relief device comprises a burst disk that bursts and fully opens when the pressure at the gas outlet exceeds a pressure relief value
Data Source
Figure 1~2
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AI summary
The invention is directed to a regulator (2) for compressed gas, comprising a body (4) with a gas inlet (6), a gas outlet (8) and a gas passage (10) fluidly interconnecting said gas inlet (6) and gas outlet (8); a pressure reducer (14) with, in the gas passage (10), a shut-off device and a movable assembly operatively connected to the shut-off device and delimiting with the body (4) a regulating chamber (14.6) downstream of the shut-off device; a pressure relief device (16) in the gas passage (10) downstream of the regulating chamber; and a flow restriction (22) in the gas passage (10) upstream of the shut-off device, dimensioned for reducing the gas pressure at the gas outlet (8) under a maximum pressure value when the pressure relief device (16) is opened and the shut-off device is opened.