Smart Pressure Relief Valve for Adaptive Leak and Overpressure Detection
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Solution Overview
Problem
Existing pressure relief valves lack the ability to adjust relief pressure thresholds based on the operating conditions of fluid systems and fail to provide insights into overpressure events or leaks, leading to potential equipment damage and safety risks.
Innovation Solution
A pressure relief valve system that includes a pressure sensor and controller to detect leaks and overpressure conditions by analyzing pressure patterns, allowing for automatic adjustment of relief pressure settings and providing data to stakeholders for corrective actions, while utilizing existing equipment and sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the relief pressure setting is disposed too high, then the pressure relief valve may not relieve a damaging overpressure when it is expected to function, but if the relief pressure setting is disposed too low, then the pressure relief valve may be activated unnecessarily too frequently
Solution Approach 1:
The pressure relief valve dynamically adjusts its relief pressure setting based on real-time monitoring of system operating conditions and learned normal pressure patterns. The controller modifies the relief threshold adaptively, allowing the valve to maintain high reliability by relieving only genuine overpressure events while avoiding false activation during normal operational variations.
Solution Approach 2:
The system incorporates continuous pressure monitoring and feedback mechanisms that analyze pressure patterns over time. The controller learns normal operating pressure ranges and uses this feedback to intelligently determine when to activate the relief valve, distinguishing between normal pressure fluctuations and dangerous overpressure conditions that require relief.
2Reliability
If a mechanical pressure relief valve is used, then the valve can relieve overpressure, but there are no indications that may be obtained from the mechanical pressure relief valve as to the event/s or causes preceding the overpressure event
Solution Approach 1:
The system implements continuous pressure monitoring with a controller that records and analyzes pressure patterns leading up to overpressure events. This feedback mechanism provides detailed information about the sequence of events, pressure trends, and potential causes preceding valve activation, enabling stakeholders to understand and address the root causes of overpressure incidents.
Solution Approach 2:
A smart controller acts as an intermediary between the mechanical pressure relief valve and the monitoring system. This intermediary component captures pressure data, analyzes patterns, and provides actionable information about overpressure events without interfering with the valve's primary relief function, thereby preserving both the mechanical reliability and information availability.
3Ease of operation
If the pressure relief valve setting is arbitrarily assigned, then the valve can be installed quickly, but it may not match the actual operating pressure of the fluid system
Solution Approach 1:
The system performs preliminary learning of normal operating pressure patterns during an initial period after installation. During this phase, the controller monitors and records pressure variations under normal conditions, establishing a baseline understanding of the system's operating characteristics before full protective functionality is activated.
Solution Approach 2:
The pressure relief valve transitions from a static, arbitrarily-set configuration to a dynamic, adaptive system that automatically adjusts its relief threshold based on learned operating patterns. This dynamic adaptation occurs automatically during system operation, eliminating the need for manual reconfiguration while maintaining ease of initial installation.
4Device complexity
If a pressure relief valve is used without leak detection capability, then the valve structure remains simple, but the valve cannot identify potential leaks in the fluid system
Solution Approach 1:
The pressure relief valve is designed as a multi-functional device that combines overpressure relief with leak detection and diagnostic capabilities. The same pressure sensing and control systems used for relief valve operation are leveraged to monitor for pressure patterns indicative of leaks, eliminating the need for separate dedicated leak detection hardware in many cases.
Solution Approach 2:
The pressure relief valve system performs self-diagnosis by analyzing its own pressure monitoring data to detect potential leaks. The controller examines pressure patterns, rate of pressure change, and other parameters to identify conditions suggestive of leaks, allowing the system to monitor its own health and alert stakeholders without requiring external diagnostic equipment.
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 effectively identifies and isolates leaks, reduces unnecessary pressure relief events, and ensures timely corrective measures, enhancing the safety and efficiency of fluid systems by providing real-time monitoring and adjustable pressure settings.
Implementation Method 1
a pressure sensor disposed on an exit of the hot side of the water heating system
Data Source
AI summary
A method for identifying the potential location of a leak in a water heating system to one of a hot side and a cold side of the water heating system, the hot side of the water heating system receives incoming water at an inlet, the hot side of the water heating system including a bypass line connected in parallel to at least one heater line, a pressure sensor disposed on an exit of the hot side of the water heating system, the cold side of the water heating system receives incoming water at the inlet, a master valve disposed on an upstream location of the inlet, a first valve disposed on the bypass line and a second valve disposed on the at least one heater line, the method includes closing the master valve; opening the master valve; and closing the first valve and the second valve.