Loading Chamber Regulator Control for Fast Shut-Off Response
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Solution Overview
Problem
During shut-off events in natural-gas power plants, the pressure within the fluid path between a first valve and a main regulator can increase, potentially triggering a relief valve and causing downtime, while low pressure events may hinder fluid flow to turbines, as the main regulator fails to actuate quickly enough.
Innovation Solution
A second valve is strategically coupled between the loading chamber and the fluid path to either evacuate or load it, allowing for rapid actuation of the main regulator by generating control signals based on shut-off or low pressure conditions, ensuring the main regulator closes or opens efficiently to prevent excess fluid flow or ensure sufficient fuel supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the main regulator actuates slowly during shut-off events, then the relief valve is triggered causing downtime, but actuating faster requires additional control mechanisms
Solution Approach 1:
The control system is segmented into multiple independent components: a first valve for primary fluid control, a second valve specifically for loading chamber evacuation, and a controller that manages their coordinated operation. This segmentation allows the loading chamber to be evacuated independently through the second valve, enabling rapid regulator closure without complicating the entire system.
Solution Approach 2:
The second valve is positioned and configured to evacuate the loading chamber before the main regulator actuation is fully completed. This preliminary action of removing pressure from the loading chamber in advance enables the main regulator to close rapidly when needed, preventing relief valve triggering during shut-off events.
2Productivity
If the main regulator actuates slowly during low pressure events, then fluid flow to turbines is hindered, but faster actuation requires additional control mechanisms
Solution Approach 1:
The control system uses a dedicated second valve separated from the main regulator actuation mechanism. This valve can be independently activated to load the loading chamber with fluid, enabling rapid regulator opening during low pressure events without requiring complex modifications to the main regulator structure.
Solution Approach 2:
The loading chamber acts as an intermediary element between the fluid supply and the main regulator. By controlling fluid pressure in this intermediate chamber through the second valve, the system can rapidly influence regulator actuation speed, enabling fast response during low pressure events while keeping the main regulator design relatively simple.
3Speed
If a second valve is added to control loading chamber pressure, then regulator actuation speed improves, but device complexity increases
Solution Approach 1:
The second valve is designed with multi-functionality to justify its addition. It serves multiple purposes: evacuating the loading chamber during shut-off events to enable rapid closure, and potentially loading the chamber during low pressure events to enable rapid opening. This multi-functionality reduces the need for even more components.
Solution Approach 2:
The second valve is integrated into the existing regulator structure and fluid pathways, allowing it to utilize available system resources. The valve controls pressure in the loading chamber which directly affects regulator actuation, making the added component work with the existing system rather than requiring separate independent mechanisms.
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
This solution enables the main regulator to close approximately 88% faster during shut-off events and ensures timely opening during low pressure conditions, preventing downtime and ensuring consistent fluid flow to turbines.
Implementation Method 1
A second valve is strategically coupled between the loading chamber and the fluid path to either evacuate or load it, allowing for rapid actuation of the main regulator by generating control signals based on shut-off or low pressure conditions
Data Source
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AI summary
Methods and apparatus to control the actuation of regulators including a loading chamber are disclosed. An example apparatus includes a first pneumatic regulator including a loading chamber, the first pneumatic regulator to flow fluid toward a downstream process; a second pneumatic regulator coupled between the loading chamber and the downstream process, the second pneumatic regulator to control an actuation of the first pneumatic regulator during normal operation based on a pressure difference between a first pressure downstream of the first pneumatic regulator and a second pressure within the loading chamber; and a valve coupled between the loading chamber and the downstream process, the valve to control the actuation of the first pneumatic regulator during a shut-down event.