Removable Heat Inducer for Gas Regulator Condensation Prevention
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Solution Overview
Problem
Existing regulators in the natural gas, petrochemical, and oil industries are ineffective in preventing condensation of gases due to inadequate heat exchange, which occurs when high-pressure pipeline fluids are reduced in pressure for analysis, leading to temperature drops and condensation issues in instrumentation systems.
Innovation Solution
A heated regulator with a body defining a heating chamber and a removable heat inducer, featuring an electrical heating element and various designs such as spiral passageways or dead-head passageways, effectively raises the temperature of fluids to prevent condensation and vaporize liquids before analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If pressure reduction is applied to step down pipeline pressure to instrument pressure, then pressure compatibility with instrumentation systems is improved, but temperature drops due to Joule-Thomson effect causing condensation of gases
Solution Approach 1:
The patent applies preliminary heating action before pressure reduction. The heating element heats the fluid in the heating chamber before the fluid enters the pressure reduction valve, preventing the temperature drop that would normally occur during pressure reduction. This resolves the contradiction by preparing the fluid in advance to withstand the cooling effect of pressure reduction.
Solution Approach 2:
The patent converts the harmful Joule-Thomson cooling effect into a beneficial controlled heating process. Instead of allowing uncontrolled temperature drop during pressure reduction, the system uses electrical heating to control the temperature, transforming the problematic thermal effect into a manageable and useful heating process.
2Temperature
If heating is applied to counter Joule-Thomson effect and prevent condensation, then temperature maintenance is improved, but heat exchange efficiency is insufficient in prior art regulators
Solution Approach 1:
The patent applies local quality by concentrating heating in a specific heating chamber with a heating element, rather than relying on distributed heating. The heating chamber is specifically designed to concentrate thermal energy where it is most needed - before the pressure reduction valve - ensuring reliable and efficient temperature maintenance.
Solution Approach 2:
The patent introduces a heating element as an intermediary between the power source and the fluid. This intermediary device directly transfers electrical energy to thermal energy in the fluid, providing a more reliable and efficient heating mechanism compared to the indirect heating methods used in prior art regulators.
3Area of stationary object
If spiral wrapped screen is used as heat exchange surface, then heat transfer area is increased, but heating effectiveness remains poor in prior art regulators
Solution Approach 1:
The patent replaces the mechanical spiral wrapped screen heat exchange surface with an electrical heating element system. This substitution eliminates the inefficiencies of conductive heat transfer through screens and directly applies electrical heating, resulting in significantly improved heating effectiveness while maintaining compact dimensions.
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 effectively prevents gas condensation and efficiently heats fluids, ensuring accurate analysis by maintaining fluid temperature and pressure compatibility with instrumentation systems, even at high pipeline pressures.
Implementation Method 1
When electrical current flows through the heating element, it heats up which warms the heat tube and the heat inducer
Implementation Method 2
A fluid contacts the heat inducer and flows through the heating chamber to raise the temperature of the fluid
Implementation Method 3
This reduction in pressure may also cause a drop in temperature due to the Joule-Thomson effect which can also cause condensation of gases
Data Source
AI summary
A removable heat inducer may be used in either a heated regulator or a fluid heater. The removable heat inducer has various embodiments. In one embodiment, helical threads are formed on the outside surface of the inducer. The inducer expands when heated causing the crest of the threads to come into contact with the inside surface of a heating chamber to form a spiral fluid passageway which promotes better heat exchange between the fluid and the heating element. In a first alternative embodiment of the inducer, a series of walled partitions and slots are formed on the outside surface of the inducer, which likewise expand and contact the inside surface of the heating chamber to form a dead head flow passageway. Again, the purpose of the passageway is to promote efficient heat exchange. In a second alternative embodiment of the removable heat inducer, a plurality of rods are placed in the heating chamber to promote heat exchange. The spaces between the rods form passageways for the fluid. The removable heat inducer may be used in a heated regulator or a fluid heater.