Pilot-Operated Pressure Regulator With Two-Path Balanced Control
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Solution Overview
Problem
Pressure regulators in the natural gas industry face challenges in maintaining accurate downstream pressure control and responding to changes in demand and temperature, especially under high inlet pressures, due to design limitations and variations in fluid flow.
Innovation Solution
The integration of a two-path control system with a balanced trim assembly and a spring-operated valve that adjusts flow based on downstream demand, allowing for modular design and enhanced pressure regulation, including a fail-to-close position for safety, accommodates high inlet pressures and ensures stable, accurate pressure control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional pressure regulator design is used, then the device structure is simple, but the downstream pressure control accuracy deteriorates under high inlet pressure and demand variations
Solution Approach 1:
The pressure regulator is divided into two independent control paths: a high-pressure path with a first valve for inlet pressure above 1500 PSI, and a low-pressure path with a second valve for inlet pressure below 1500 PSI. Each path has its own valve assembly, trim, and control mechanism, allowing optimized control accuracy for each pressure range while managing overall device complexity through modular segmentation.
Solution Approach 2:
The regulator dynamically switches between the first valve and second valve based on inlet pressure conditions. A pressure sensor continuously monitors inlet pressure and controls the first valve to open or close, transitioning control to the appropriate valve assembly. This dynamic adaptation maintains optimal control accuracy across varying pressure conditions without requiring a completely complex redesign for all scenarios.
2Stress or pressure
If the valve operates at high inlet pressure (at least 1500 PSI), then the operating pressure capacity increases, but the control variations from inlet pressure changes and temperature effects worsen
Solution Approach 1:
The valve assembly is segmented into a first valve for high-pressure operation (≥1500 PSI) and a second valve for lower-pressure operation (<1500 PSI). The first valve is specifically designed and optimized for high-pressure capacity, while the second valve handles lower-pressure conditions. This segmentation allows each valve to be tailored for its specific pressure range, maintaining control stability within each range while achieving high overall operating pressure capacity.
Solution Approach 2:
The system changes operational parameters by switching between different valve assemblies based on inlet pressure. When inlet pressure exceeds 1500 PSI, the first valve assembly is activated with parameters optimized for high-pressure control. When pressure drops below 1500 PSI, the system transitions to the second valve assembly with parameters suited for lower-pressure operation, thereby maintaining control stability across the full pressure range.
3Speed
If a single valve assembly is used, then the device complexity is low, but the response time to demand changes deteriorates
Solution Approach 1:
The control system is segmented into two parallel valve assemblies, each capable of independent operation. The first valve assembly with its dedicated trim and control mechanism can respond to demand changes in the high-pressure range, while the second valve assembly handles lower-pressure demand changes. This parallel segmentation enables faster overall response time by having dedicated control paths ready for different pressure conditions, rather than relying on a single valve to handle all transitions.
Solution Approach 2:
Both valve assemblies are pre-configured and ready for operation within their respective pressure ranges. The pressure sensor continuously monitors conditions and pre-positions the appropriate valve for quick activation. This preliminary preparation of multiple valve assemblies ensures that when demand changes occur, the system can immediately switch to the pre-configured appropriate valve, reducing response time without requiring complex real-time adjustment mechanisms.
4Measurement precision
If the valve opens frequently to meet downstream demand, then the downstream pressure control accuracy improves, but the wear and maintenance requirements worsen
Solution Approach 1:
The valve assemblies are segmented into modular units with separate trim components for the first valve and second valve. Each trim assembly can be independently removed, inspected, and maintained. This modular segmentation allows maintenance personnel to service only the specific valve trim that requires attention, rather than disassembling and maintaining an entire integrated valve system, thereby reducing overall maintenance complexity and time.
Solution Approach 2:
The trim assemblies are designed as replaceable components that can be easily removed and replaced during maintenance. When trim components wear from frequent operation, they can be discarded and replaced with new trim assemblies without replacing the entire valve body or control mechanism. This approach recovers the valuable valve housing and control systems while replacing only the worn consumable trim parts, reducing maintenance costs and time.
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 design provides improved accuracy and reliability in maintaining downstream pressure, increased operating pressure capacity, and simplified maintenance through modular construction, effectively addressing the challenges of high-pressure applications and demand variations.
Implementation Method 1
The valve opens from this position to allow fluid to flow through the device to maintain downstream pressure at a relatively constant level
Implementation Method 2
Nominally, the valve has an 'equilibrium' position that maintains pressure equally on both upstream and downstream sides of the device
Implementation Method 3
Pressure regulators are useful to control downstream pressure of fluids
Data Source
AI summary
A pressure regulator is configured for better accuracy and response times at higher inlet pressures. These configurations may integrate two-path control with a pressure-balanced plug. The two-path control may leverage a pair of pilot valves, one with a fixed differential pressure and the other with a variable differential pressure. In one implementation, the device is plumbed so that downstream pressure is sensed at both the actuator and the variable differential pressure pilot valve.