Multiple-Stage Valve System Actuation Design
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Solution Overview
Problem
Prior multiple-stage valve systems face limitations due to differences in pressure between process fluid and pilot fluid, leading to larger valve blocks and susceptibility to pressure variations, which increase manufacturing costs and reduce efficiency.
Innovation Solution
The system uses process fluid to actuate the main control valve between positions, maintaining constant cross-sectional areas for biasing pistons across a wide pressure range, with the second pilot valve controlled by process fluid rather than pilot fluid, allowing for a smaller valve block design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pilot fluid is used to actuate the main control valve, then the valve can be controlled, but the valve block size increases and manufacturing costs increase
Solution Approach 1:
The patent extracts the second stage pilot valve from the traditional pilot fluid actuation system and replaces it with direct process fluid actuation. This removes the need for pilot fluid supply lines and associated components, reducing valve block size while maintaining control capability through the remaining first stage pilot valve.
Solution Approach 2:
The patent uses process fluid as an intermediary to directly actuate the main control valve's biasing piston, eliminating the need for pilot fluid as the intermediary medium. This substitution reduces system complexity and valve block size while preserving the control function.
2Reliability
If traditional multiple-stage valve system with pilot fluid is used, then valve control is achieved, but the system is susceptible to pressure variations between process fluid and pilot fluid
Solution Approach 1:
The patent makes process fluid serve multiple functions: it acts as both the controlled medium and the actuating medium for the main control valve. This eliminates the need for a separate pilot fluid system and ensures pressure ratio consistency since the same fluid is used throughout, making the system universally adaptable without pressure variation susceptibility.
3Volume of stationary object
If process fluid is used to actuate the main control valve, then the valve block size is reduced, but the system configuration must be changed
Solution Approach 1:
The patent extracts and removes the second stage pilot valve and its associated pilot fluid supply system from the traditional configuration. This extraction simplifies the overall system configuration while reducing valve block size, as the remaining first stage pilot valve directly controls the main control valve using process fluid actuation.
4Force
If pilot fluid pressure is much less than process fluid pressure, then less force is required for the pilot valve, but the valve block size increases
Solution Approach 1:
The patent uses process fluid as a direct intermediary to actuate the main control valve's biasing piston, eliminating the need for a separate pilot fluid intermediary system. This substitution reduces valve block size while the first stage pilot valve maintains adequate control force through its dedicated pilot fluid supply at appropriate pressure levels.
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 approach reduces the size of the valve block, enhances manufacturing efficiency, and maintains consistent force ratios independent of process fluid pressure, improving the system's operational stability and cost-effectiveness.
Implementation Method 1
process fluid from the process fluid supply acts on both the first pressure actuated biasing member and the second pressure actuated biasing member of the main control valve
Implementation Method 2
the ratio of forces acting on the two biasing members is constant and independent of the process fluid pressure
Implementation Method 3
a second port selectively in fluid communication with the first port
Data Source
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AI summary
A multiple - stage valve system (200) including a pilot fluid supply (209) and a process fluid supply (222) is provided. The multiple - stage valve system includes a first pilot valve (201) including a first port (206) in fluid communication with the pilot fluid supply and a second port (207) selectively in fluid communication with the first port. The multiple - stage valve system also comprises a second pilot valve (202). The second pilot valve can include a first port (213) in fluid communication with the process fluid supply and a second port (214) selectively in fluid communication with the first port. The second pilot valve also includes a first pressure - actuated biasing member (217) in fluid communication with the process fluid supply and a second pressure - actuated biasing member (218) in fluid communication with the second port of the first pilot valve. The multiple - stage valve system also comprises a main control valve (203). The main control valve can include a first port (220) in fluid communication with the process fluid supply and a second port (221) selectively in fluid communication with the first port. The main control valve can also include a first pressure- actuated biasing member (225) in fluid communication with the process fluid supply and a second pressure- actuated biasing (226) member in fluid communication with the second port of the second pilot valve.