Process Valve Actuator Layout for Zero-Emission Hydraulic Control
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Solution Overview
Problem
Conventional gas-over-oil control valve systems face issues such as loud noise and high velocity flow due to exhaust of process fluid to atmosphere, lack of a fail-safe mechanism, and contamination of hydraulic fluid by impurities from the process fluid, which can damage components.
Innovation Solution
A control valve assembly with a control fluid power apparatus that uses accumulators charged by process fluid pressure, allowing fluid to flow back to the pipeline, reducing noise and contamination, and employing a directional controller and thermal volume controller to maintain constant pressure and torque output, and orienting components to facilitate impurity gravitation back into the pipeline.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If process fluid is exhausted to atmosphere after pressurizing hydraulic fluid, then the control valve can be actuated, but loud noise and high velocity flow are produced
Solution Approach 1:
The patent introduces an intermediary fluid (inert gas or liquid) that acts as a mediator between the process fluid and the hydraulic system. The process fluid pressurizes this intermediary fluid, which then transfers energy to actuate the control valve without direct contact with the atmosphere, eliminating noise and high velocity flow emissions.
Solution Approach 2:
The patent converts the potentially harmful exhaust of process fluid to atmosphere into a beneficial closed-loop system where the intermediary fluid is contained and reused. The energy that would have been wasted in noisy atmospheric exhaust is instead utilized to pressurize and recycle the intermediary fluid, benefiting from the same energy source without the harmful effects.
2Device complexity
If process fluid directly engages hydraulic oil in pressure vessels, then the system is simple, but impurities contaminate the hydraulic fluid and damage components
Solution Approach 1:
The patent introduces an intermediary fluid as a protective mediator between the process fluid and hydraulic oil. This intermediary fluid absorbs impurities from the process fluid through gravity and density differences, preventing contamination of the hydraulic oil while maintaining system functionality with minimal added complexity.
Solution Approach 2:
The patent segments the fluid system into distinct layers: process fluid, intermediary fluid, and hydraulic oil. This segmentation allows each fluid to perform its specific function while being physically separated by density differences, preventing direct mixing and contamination while maintaining overall system simplicity.
3Power
If pressure vessels have large volumes to store hydraulic fluid, then sufficient power is available, but 15 to 20 seconds are required to fill and evacuate process fluid
Solution Approach 1:
The patent changes the physical parameters of the fluid system by using an intermediary fluid with different density and compressibility characteristics. This allows for smaller volume pressure vessels to achieve the same power storage capacity, reducing the time required to fill and evacuate while maintaining sufficient hydraulic power for valve actuation.
4Device complexity
If gas-over-oil systems lack a spring mechanism, then the system is simpler, but no fail-safe mechanism is provided
Solution Approach 1:
The patent implements a self-service fail-safe mechanism where the intermediary fluid automatically responds to system failures. In the event of a failure, the intermediary fluid's density and pressure characteristics automatically restore the valve to a safe position without requiring external spring mechanisms or complex control systems, maintaining simplicity while ensuring safety.
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 solution achieves zero process fluid emissions, constant pressure and torque output, and increased operational life by preventing contamination and noise, while eliminating the need for pressure switches and reducing component damage.
Implementation Method 1
The first process fluid is positioned below the first piston and the second process fluid is positioned above the first piston. The first process fluid causes the first piston to move, which directs flow of the first hydraulic fluid.
Implementation Method 2
The first process fluid causes the first piston to move, which directs flow of the first hydraulic fluid
Implementation Method 3
The second process fluid is positioned below the second piston and a third process fluid is positioned above the second piston. The second process fluid causes the second piston to move, which directs flow of the second hydraulic fluid.
Implementation Method 4
The second process fluid causes the second piston to move, which directs flow of the second hydraulic fluid
Implementation Method 5
A directional controller directs fluid flow between the first chamber of the first accumulator and at least one of the first cavity or the second cavity of the actuator
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The control fluid power apparatus (102) includes a first housing (226) having a first piston (228) defining a first chamber (232) and a second chamber (236), where the first chamber (232) receives a control fluid (220) and the second chamber (236) receives a process fluid (235) from a process system (104). The first chamber (232) is oriented above the second chamber (236) when the control fluid power apparatus (102) is coupled to a control valve assembly (100). A second housing (244) has a second piston (246) defining a third chamber (250) and a fourth chamber (254), where the third chamber (250) receives the control fluid (220) and the fourth chamber (254) receives the process fluid (235). The third chamber (250) is oriented above the fourth chamber (254) when the control fluid power apparatus (102) is coupled to the control valve assembly (100).