Thermo-Electric Valve for Methane Flow Interruption
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Solution Overview
Problem
In pneumatic process heating systems used in the oil and gas industry, there are no effective controls to stop the release of unburned methane from pilot and main burners when the pilot flame is lost due to blockage, freezing, or wind, leading to continuous methane emission into the atmosphere until gas supply runs out or equipment can be accessed.
Innovation Solution
A low-cost, zero external power, thermo-electro pneumatic apparatus is introduced to cease methane flow from a high-pressure source to a gas heating system by using a pneumatic signal selector, thermo-electric valve, and thermostatic controller to detect flame loss and control the methane flow accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pneumatic process heating system operates without flame loss detection controls, then the system maintains simple operation and low cost, but methane continues to flow uncontrolled into the atmosphere after pilot flame loss
Solution Approach 1:
The system uses the pilot flame's own thermal energy to generate the voltage signal through the thermocouple that controls the gas flow. The thermocouple converts the flame's heat directly into electrical signal that operates the thermo-electric valve, making the safety system self-powered and eliminating need for external power sources or complex electronic controls
Solution Approach 2:
The patent replaces complex electronic burner management systems with a simpler thermo-electric mechanism. The thermocouple and thermo-electric valve create a direct thermal-to-mechanical conversion system that is more reliable in remote locations without electrical grid access
2Reliability
If an electronic burner management system is installed to detect flame loss, then methane flow control improves, but system cost increases significantly
Solution Approach 1:
The system uses inexpensive thermocouple and thermo-electric valve components instead of expensive electronic burner management systems. These simpler components are sufficient for the application and dramatically reduce the cost barrier for implementing flame loss detection in remote oil and gas operations
Solution Approach 2:
The thermocouple generates its own power from the pilot flame heat, eliminating need for external power sources. This self-powered mechanism makes the system economically viable for remote locations where installing and maintaining expensive electronic systems would be prohibitively costly
3Reliability
If external power sources are used for flame detection systems, then detection reliability improves, but system becomes dependent on grid or solar access which may be unavailable
Solution Approach 1:
The thermocouple converts the pilot flame's thermal energy directly into electrical voltage, making the system completely self-powered. This eliminates dependency on external power sources like electrical grid or solar panels, enabling reliable operation in remote locations regardless of weather conditions or grid availability
Solution Approach 2:
The system changes the energy parameter from requiring external electrical power to using thermal energy from the pilot flame itself. This parameter transformation enables the system to operate independently of external power infrastructure
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 apparatus effectively stops fugitive methane emissions from both pilot and main burners upon loss of the pilot flame, ensuring environmental safety and reducing operational costs by eliminating unnecessary gas consumption.
Implementation Method 1
a thermocouple in thermal contact with the pilot methane gas burner, the thermocouple providing a voltage responsive to a temperature generated when the pilot methane gas burner has a flame
Implementation Method 2
a thermo-electric valve for receiving the output pressure of methane from the pneumatic signal selector, for receiving the voltage from the thermocouple, for providing an output pressure of methane equal to the output pressure from the pneumatic signal selector, and for providing a control signal
Implementation Method 3
a pneumatic gas regulator for receiving methane from the high-pressure methane source and for providing a first chosen pressure of methane
Data Source
AI summary
A low cost, pneumatic, thermo-electric apparatus and method capable of controlling both a pilot gas burner and a main heating gas burner for ensuring cessation of fugitive methane emissions from process heating systems upon loss of the pilot flame, without requiring external electricity, are described.