Shut-off and test valve with spherical shutter for gas plants
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Solution Overview
Problem
Existing shut-off and test valves for gas plants fail to prevent accidental gas leaks during normal operation and can cause damage by injecting test gas at excessive pressures or mixing it with the supply network, posing safety risks.
Innovation Solution
A shut-off and test valve design with a hollow spherical shutter and multiple seal gaskets ensures that the test gas inlet is isolated from the main gas supply and distribution network, preventing leaks and excessive pressure issues through precise positioning and dimensioning of openings and seal gaskets, allowing only controlled communication between the inlet, outlet, and test gas inlet during testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the test gas inlet opening is left open after testing operations, then the valve cannot prevent gas leakage during normal functioning, but adding protective mechanisms increases device complexity
Solution Approach 1:
The valve internal space is segmented into distinct functional zones using the spherical shutter with selectively positionable openings. The shutter divides the valve body into separate pathways for normal gas flow and test gas injection, ensuring that the test gas inlet opening is isolated from the main flow path during normal operation. This segmentation prevents gas leakage without requiring additional complex protective mechanisms.
Solution Approach 2:
The spherical shutter is pre-configured with openings positioned to automatically isolate the test gas inlet opening from the normal gas flow path when the valve is in the normal operating position. This preliminary arrangement of the shutter geometry ensures that even if the test gas inlet opening is accidentally left open, the segmented design prevents gas leakage without requiring active protective mechanisms.
2Reliability
If test gas is injected at excessive pressure during testing, then the counter and supply network may be damaged, but adding pressure control mechanisms increases device complexity
Solution Approach 1:
The valve internally segments the test gas injection path from the counter and supply network using the spherical shutter. When the shutter is in the normal operating position, its geometry ensures that the test gas inlet opening is completely isolated from the counter and supply network, even if excessive pressure is applied during testing. This segmentation provides passive protection without requiring active pressure control mechanisms.
3Reliability
If the test gas inlet is connected to the supply network, then test gas may mix with combustible gas, but ensuring complete isolation increases manufacturing precision requirements
Solution Approach 1:
The spherical shutter employs local quality by positioning specific openings at specific locations on the sphere surface. The openings are strategically positioned so that in the normal operating position, the shutter geometry itself creates complete isolation between the test gas inlet and the supply network. This localized positioning approach ensures gas mixing prevention through the inherent geometry rather than requiring extreme manufacturing precision across the entire valve.
Solution Approach 2:
The use of a spherical shutter provides geometric advantage for isolation. The curved surface of the sphere allows openings to be positioned at optimal locations that maximize separation between gas paths. The spherical geometry naturally facilitates complete isolation of the test gas inlet from the supply network in the normal operating position, reducing the stringency of manufacturing precision requirements compared to flat or angular configurations.
Data Source
Figure 1~1A
Figure 2~4
Figure 5~7
AI summary
A shut-off and test valve (1, 101) for gas plants comprising a valve base body (2, 102) having an inlet (4, 104), an outlet (3, 103) and a further inlet (20, 120), a hollow spherical shutter (11, 111) provided with a first opening (16, 116), a second opening (17, 117) and a third opening (12, 112); the valve being exclusively configurable between an activating condition, a test condition and a security condition in which the shutter (11, 111) is positioned such as to prevent any fluid communication between the inlet (4, 104), the outlet (3, 103) and a further inlet (20, 120) of the valve body (1, 102).