Modular Diaphragm Piston Actuator With Redundant Sealing
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Solution Overview
Problem
Conventional diaphragm actuators for valves in mineral recovery wells face issues such as unsupported diaphragm regions leading to failure, leaks between the indicator stem and sealing nut, and damage from manual actuation, which necessitate improved support and sealing mechanisms.
Innovation Solution
A modular valve actuator system that can function as a diaphragm, piston, or dual actuator, featuring a non-rising stem design with a fully supported diaphragm and redundant sealing systems to prevent leaks and damage, allowing external actuation without force on the stem and enabling easy replacement without breaking seals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the diaphragm support plate outer diameter does not extend to the housing inner diameter, then the actuator structure is simpler and easier to manufacture, but the unsupported diaphragm region becomes more prone to failure and requires thicker reinforcement
Solution Approach 1:
The patent extends the support plate in the radial dimension to fully contact the housing inner diameter, eliminating unsupported diaphragm regions. This dimensional extension provides complete support across the diaphragm surface, preventing failure without requiring additional thickness reinforcement.
2Reliability
If the indicator stem sealing nut sealingly engages the plate bore, then the sealing is more reliable, but the sealing nut must be removed to replace the diaphragm and manual actuation can damage the stem or internal components
Solution Approach 1:
The patent segments the actuator into modular components: the diaphragm assembly can be independently removed from the housing without disturbing the sealed indicator stem assembly. This segmentation allows diaphragm replacement while maintaining the integrity of the sealing nut and stem connection.
Solution Approach 2:
The patent extracts the diaphragm replacement function from the sealing nut assembly. The diaphragm can be accessed and replaced through a separate access point or by removing only the diaphragm-specific components, leaving the sealed indicator stem and sealing nut intact and undisturbed.
3Ease of operation
If manual force is applied to the indicator stem for actuation, then the valve can be manually operated, but the force can damage the stem or internal components of the actuator
Solution Approach 1:
The patent introduces a force-distributing intermediary mechanism between the manual actuation input and the indicator stem. This intermediary distributes the applied force across multiple points or uses a mechanical advantage system, preventing concentrated loads that could damage the stem or internal components while still enabling manual operation.
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 system provides extended diaphragm life by preventing wear, reducing seal failures, and allowing for flexible actuation modes while maintaining pressure integrity, enhancing manufacturing, assembly, and cost efficiency.
Implementation Method 1
a diaphragm is moved in response to pressure media, such as gas or other fluids, urging the diaphragm toward the gate valve
Implementation Method 2
it urges the support plate downward, which then transfers the downward force via a stem to the gate of the gate valve
Data Source
AI summary
An apparatus for actuating a valve includes an actuator with a cap. A plate that engages the inner diameter of the actuator housing is positioned within the actuator housing. A pressure chamber is located within the actuator housing between the plate and cap. A cap seal fluidly seals the pressure chamber between the cap and the actuator housing. The pressure chamber is fluidly sealed at the plate by one of a first plate seal assembly and a second plate seal assembly. The first plate seal assembly is formed by the diaphragm being secured between a seal nut and the plate. The second plate seal assembly is formed by an outer diameter sidewall seal located between the inner diameter of the actuator housing and the outer diameter of the plate and a retainer seal located between an outer diameter of the seal nut and an inner diameter of the plate.