Gas Valve Overpressure Diagnostics via Integrated Sensors
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Solution Overview
Problem
Gas valve assemblies lack effective overpressure diagnostics and monitoring capabilities, which can lead to safety issues and inefficiencies in gas-fired appliances, as existing systems do not adequately detect and respond to high or low gas pressures, and fail to perform reliable valve proving system tests.
Innovation Solution
Incorporating pressure sensors and a valve controller into the gas valve assembly to monitor inlet and outlet pressures, detect overpressure events, and perform diagnostic functions, including valve proving system tests, to ensure safe operation and efficient gas flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pressure sensors and valve controller are integrated into the gas valve assembly, then overpressure detection and diagnostic capabilities are improved, but device complexity increases
Solution Approach 1:
The patent integrates pressure sensors and a valve controller directly into the gas valve assembly, combining multiple functions (pressure sensing, control logic, valve actuation) into a single unified device. This merging approach improves reliability by ensuring coordinated operation of sensing and control elements while eliminating the need for separate external monitoring systems.
Solution Approach 2:
The valve controller serves multiple functions: it actuates the valve based on control signals, monitors pressure sensor readings, performs overpressure detection, executes valve proving system tests, and provides diagnostic capabilities. This multi-functionality reduces the need for separate dedicated components for each function.
2Measurement precision
If multiple pressure sensors are installed to monitor both inlet and outlet pressures, then measurement precision is improved, but device complexity increases
Solution Approach 1:
Pressure sensors are strategically positioned at specific locations within the valve assembly (inlet and outlet ports) to measure pressure at the most relevant points for overpressure detection and valve proving tests. This localized sensing approach provides precise measurement where it is most needed without requiring sensors throughout the entire gas flow path.
3Reliability
If valve proving system tests are performed to ensure reliable valve closure, then safety is improved, but loss of time occurs during testing
Solution Approach 1:
The valve controller performs proving system tests as a preliminary action before allowing normal gas flow operation. By conducting these verification tests in advance, the system ensures valve reliability is confirmed before operation begins, preventing potential safety issues during actual use.
Solution Approach 2:
The proving system tests are designed to be performed continuously or periodically during valve operation, rather than requiring separate dedicated testing time. The controller can execute diagnostic routines that verify valve closure functionality while the system remains in normal operation, minimizing interruption to useful gas flow control.
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 enables real-time monitoring and response to pressure changes, preventing overpressure events, optimizing gas flow, and ensuring the reliability and safety of gas-fired appliances by integrating pressure sensing and control within the valve assembly.
Implementation Method 1
The pressure sensor may be configured to sense a first pressure in a fluid or fuel in the valve body and communicate a measure related to the sensed first pressure to a valve controller
Data Source
AI summary
This disclosure relates generally to valves, and more particularly, to gas valve assemblies. In one example, a gas valve assembly may include a valve body with one or more valves movable between an opened position and a closed position, one or more valve actuators configured to operate the valves, and one or more pressure sensors to sense a pressure within a fluid path of the valve assembly. A valve controller may receive a measure related to a sensed pressure from the one or more pressure sensor(s). The valve controller may compare the received measure related to the sensed pressure to an overpressure threshold. In the event the measure related to the sensed pressure surpasses the overpressure threshold value, the valve controller may be configured to provide a signal that indicates an overpressure event has occurred.