In-line Back Pressure Regulator Compact Tubing Design
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Solution Overview
Problem
Conventional back-pressure regulators are too large for applications with small tubing diameters, such as gas exploration, where they are needed to manage pressure fluctuations and prevent damage from erosive conditions, due to their size and the transfer of full load to the flow control member and valve seat.
Innovation Solution
The development of in-line back pressure fluid regulators with a compact design that includes a housing with a coaxially aligned fluid flow path, a pressure sensor, and a loading chamber isolated from the fluid flow path, which provides a pre-set pressure reference unaffected by environmental or fluid pressure fluctuations, allowing for precise control and reduced wear on components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional back pressure regulator is used, then pressure control function is provided, but the device size is too large for small tubing diameters
Solution Approach 1:
The patent applies nesting by placing the back pressure regulator components inside the existing tubing structure. The flow control member is positioned within the tubing, and the valve seat is formed on the inner surface of the tubing, effectively nesting the regulator functionality within the tubing diameter rather than requiring external mounting space.
Solution Approach 2:
The patent transitions from a conventional external regulator design to an in-line design where the regulator components are arranged along the longitudinal axis of the tubing. The flow control member moves axially within the tubing, and the valve seat is formed on the inner circumference, utilizing the internal dimensional space of the tubing effectively.
2Reliability
If full load is transferred to the flow control member and valve seat, then pressure regulation is achieved, but component wear increases and reliability decreases
Solution Approach 1:
The patent segments the load bearing function from the flow control function. The valve seat is formed on the tubing inner surface rather than being part of the flow control member, separating the stationary seating surface from the moving control element. This segmentation allows the flow control member to open and close the valve without carrying the full seat load, reducing wear on both components.
Solution Approach 2:
The patent extracts the valve seat from the flow control member assembly and forms it directly on the tubing inner surface. This extraction removes the valve seat from the moving parts, allowing it to remain stationary and better positioned to withstand the full regulatory load while the flow control member only performs the opening/closing action with reduced wear.
3Reliability
If conventional regulator design is used, then pressure sensing is provided, but the device cannot be installed in-line with small diameter tubing
Solution Approach 1:
The patent merges the pressure sensing function with the flow control function by positioning the pressure sensor to act directly on the flow control member. The sensor, seal, and flow control member are integrated into a single in-line assembly that fits within the tubing, combining multiple functions into one compact unit that can be installed internally without external connections.
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 in-line design reduces the risk of damage to the valve plug and seat, maintains pressure control, and fits within smaller spaces, ensuring reliable operation and extended component life by decoupling the load from the flow control member and valve seat during pressure fluctuations.
Implementation Method 1
A biasing element disposed within the loading chamber and providing a pre-set pressure reference
Implementation Method 2
a pressure sensor such as a piston to sense the pressure of a pressurized fluid at an inlet of the regulator
Implementation Method 3
the pressure sensor causes a flow control member of the fluid valve to open to allow fluid flow through the regulator body between the inlet and an outlet
Data Source
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AI summary
In-line back pressure fluid regulators are described. An example in-line fluid regulator includes a regulator body defining a sensing chamber and an outlet of a fluid flow path of the fluid regulator. The outlet is in fluid communication with the sensing chamber via a first flow passageway in the regulator body. A bonnet is coupled to the regulator body and defines an inlet of the fluid flow path and a loading chamber disposed between the sensing chamber and the inlet. The loading chamber is substantially sealed relative to the fluid flow path of the fluid regulator. A pressure sensor is disposed between the inlet and the sensing chamber, where the pressure sensor defines a second flow passageway to fluidly couple the inlet and the sensing chamber.