Flow control valve with integral sensor and controller and related method

• US 6,892,745 B2
• Filed: 04/10/2002
• Issued: 05/17/2005
• Est. Priority Date: 04/10/2002
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Benson, Dwayne M.
• Primary Examiner(s): LEE, KEVIN L
• Application Number:
  US10/119,686
• Publication Number:
  US 20030192595A1
• Time in Patent Office: 1,133 Days
• Field of Search: 137/14, 137/488, 137/1, 137/489
• US Class Current: 137/1
• CPC Class Codes: G01F 1/363 with electrical or electro-mechanical indication G01F1/37 and G01F1/38 take precedence
• CPC Class Codes: G05D 7/005 characterised by the use of auxiliary non-electric power combined with the use of electric means
• CPC Class Codes: Y10T 137/0318 Processes
• CPC Class Codes: Y10T 137/7762 Fluid pressure type
• CPC Class Codes: Y10T 137/7764 Choked or throttled pressure type

Abstract

A flow control valve assembly, and a method of determining and controlling fluid flow through the valve, that is relatively simple in design, is relatively inexpensive, is accurate, and has a relatively wide measurement range. The flow control valve is relatively compact and includes all of the flow measurement and control components in a single, relatively compact assembly. Such components may include a differential pressure sensor, pressure sensor, a temperature sensor, a position sensor, and a processor. The differential pressure sensor senses differential pressure across the variable area flow orifice. The pressure sensor senses fluid pressure within the valve and supplies a fluid pressure signal. The temperature sensor senses fluid temperature and supplies a fluid temperature signal. The position sensor senses the position of the variable area flow orifice and supplies a position signal. The processor receives the differential pressure signal, the fluid pressure signal, the fluid temperature signal, and the position signal and uses these signals to determine and control fluid flow parameter in the passageway.

Claims

1. A valve for measuring and controlling a fluid flow parameter, comprising:

a valve assembly having an inlet, an outlet, and a passageway therebetween;

a variable area flow orifice mounted in the passageway;

a differential pressure sensor operable to sense a differential pressure across the variable area flow orifice and supply a differential pressure signal;

an upstream conduit having an inlet coupled to the passageway upstream of the variable area flow orifice and an outlet coupled to the differential pressure sensor;

a downstream conduit having an inlet coupled to the passageway downstream of the variable area flow orifice and an outlet coupled to the differential pressure sensor;

a flow venturi coupled to the downstream conduit inlet and positioned proximate the variable area flow orifice;

a pressure sensor coupled to the passageway, the pressure sensor operable to sense fluid pressure within the passageway and supply a fluid pressure signal;

a temperature sensor coupled to the passageway and operable to sense fluid temperature and supply a fluid temperature signal;

a position sensor operable to sense a position of the variable area flow orifice and supply a position signal; and

a processor coupled to receive the differential pressure signal, the fluid pressure signal, the fluid temperature signal, and the position signal and operable to determine the fluid flow parameter in the passageway therefrom.

2. The valve of claim 1, wherein the processor generates an orifice position control signal based on the determined fluid flow parameter, and wherein the valve further comprises:

an actuator assembly coupled to receive the orifice position control signal from the processor and operable, in response thereto, to vary an area of the variable area flow orifice, whereby fluid flow parameter through the passageway is controlled.

3. The valve of claim 1, wherein:

the variable area flow orifice is a butterfly valve that is rotationally mounted in the passageway via a shaft; and

the flow venturi is positioned proximate the shaft.

4. The valve of claim 1, wherein the pressure sensor is a static pressure sensor.

5. The valve of claim 1, wherein the pressure sensor is a total pressure sensor.

6. The valve of claim 2, wherein the actuator assembly comprises:

a torque motor coupled to receive the orifice position control signals from the processor and operable, in response thereto, to vary a control pressure magnitude in a control pressure line;

an actuator housing having at least a control pressure port coupled to the control pressure line; and

a piston assembly slidably mounted within the actuator housing, the piston assembly having a first end in fluid communication with the control pressure port and a second end coupled to the variable area flow orifice,

wherein variation in the control pressure magnitude causes translation of the piston assembly and variation of the area of the variable area flow orifice.

7. The valve of claim 1, wherein the temperature sensor senses fluid temperature upstream of the variable area flow orifice.

8. The valve of claim 1, wherein the temperature sensor senses fluid temperature downstream of the variable area flow orifice.

9. The valve of claim 1, wherein the pressure sensor is coupled to the passageway upstream of the variable area flow orifice.

10. The valve of claim 1, wherein the pressure sensor is coupled to the passageway downstream of the variable area flow orifice.

11. A valve for measuring and controlling a fluid flow parameter, comprising:

a valve assembly having an inlet, an outlet, and a passageway therebetween;

a variable area flow orifice mounted in the passageway;

a differential pressure sensor operable to sense a differential pressure across the variable area flow orifice and supply a differential pressure signal;

an upstream conduit having an inlet coupled to the passageway upstream of the variable area flow orifice and an outlet coupled to the differential pressure sensor;

a downstream conduit having an inlet coupled to the passageway downstream of the variable area flow orifice and an outlet coupled to the differential pressure sensor;

a flow venturi coupled to the downstream conduit inlet and positioned proximate the variable area flow orifice;

a pressure sensor coupled to the passageway, the pressure sensor operable to sense fluid pressure within the passageway and supply a fluid pressure signal;

a temperature sensor coupled to the passageway and operable to sense fluid temperature and supply a fluid temperature signal;

a position sensor operable to sense a position of the variable area flow orifice and supply a position signal;

a processor coupled to receive the differential pressure signal, the upstream fluid pressure signal, the fluid temperature signal, and the position signal and operable to (i) determine the fluid flow rate in the passageway therefrom, and (ii) generate an orifice position control signal based on the determined fluid flow rate; and

an actuator coupled to receive the orifice position control signal from the processor and operable, in response thereto, to vary an area of the variable area flow orifice, whereby fluid flow rate through the passageway is controlled.

12. A flow control valve for controlling the flow of a fluid in one or more parts of a system, the valve comprising:

a) a valve assembly including;

(i) a passageway having a flow passage extending between a fluid inlet and a fluid outlet, and

(ii) a valve disk rotationally mounted within the flow passage and moveable through a plurality of positions each corresponding to a different flow area;

b) a temperature sensor coupled to the passageway and operable to sense fluid temperature and supply a fluid temperature signal; and

c) a housing assembly coupled to the valve assembly, the housing assembly enclosing;

(i) a first pressure sensor in fluid communication with the passageway and operable to sense a first fluid pressure within the passageway and supply a first fluid pressure signal,

(ii) a second pressure sensor coupled to the duct, the second pressure sensor operable to sense fluid pressure within the passageway and supply a second fluid pressure signal,

(iii) a position sensor coupled to the valve element, the position sensor operable to sense a position of the valve element and supply a position signal, and

(iv) a processor coupled to receive the first fluid pressure signal, the second fluid pressure signal, the fluid temperature signal, and the position signal and operable to determine a fluid flow parameter through the passageway therefrom.

13. The valve of claim 12, wherein the processor generates a valve position control signal based on the determined fluid flow parameter, and wherein the housing further encloses:

an actuator assembly coupled to receive the orifice position control signal from the processor and operable, in response thereto, to move the valve disk, whereby fluid flow parameter through the passageway from the fluid inlet to the fluid outlet is controlled.

14. The valve of claim 12, further comprising:

a cooler positioned within the housing proximate the processor for removing heat therefrom.

15. The valve of claim 14, wherein the cooler comprises an active cooler.

16. The valve of claim 15, wherein the active cooler is a thermoelectric cooler.

17. The valve of claim 12, wherein the first pressure sensor is a differential pressure sensor, and the first fluid pressure signal is a differential pressure signal, and wherein the valve further comprises:

an upstream conduit having an inlet coupled to the passageway upstream of the valve element and an outlet coupled to the pressure sensor housing and in fluid communication with the differential pressure sensor;

a downstream conduit having an inlet coupled to the passageway downstream of the valve element and an outlet coupled to the pressure sensor housing and in fluid communication with the differential pressure sensor; and

a flow venturi coupled to the downstream conduit inlet.

18. The valve of claim 17, wherein the flow venturi is positioned within the passageway proximate the valve disk.

19. The valve of claim 17, wherein the second pressure sensor is a static pressure sensor.

20. The valve of claim 17, wherein the second pressure sensor is a total pressure sensor.

21. The valve of claim 13, wherein the actuator assembly comprises:

a torque motor coupled to receive the orifice position control signals from the processor and operable, in response thereto, to vary a control pressure magnitude in a control pressure line;

an actuator housing having at least a control pressure port coupled to the control pressure line; and

a piston assembly slidably mounted within the actuator housing, the piston assembly having a first end in fluid communication with the control pressure port and a second end coupled to the variable area flow orifice,

wherein variation in the control pressure magnitude causes translation of the piston assembly and variation of the area of the variable area flow orifice.

22. The valve of claim 12, wherein the temperature sensor senses fluid temperature upstream of the variable area flow orifice.

23. The valve of claim 12, wherein the temperature sensor senses fluid temperature downstream of the variable area flow orifice.

24. The valve of claim 17, wherein the second pressure sensor is coupled to the passageway upstream of the variable area flow orifice.

25. The valve of claim 17, wherein the second pressure sensor is coupled to the passageway downstream of the variable area flow orifice.

26. A valve for measuring and controlling a fluid flow parameter, comprising:

a valve assembly having an inlet, an outlet, and a passageway therebetween;

a variable area flow orifice mounted in the passageway;

a differential pressure sensor operable to sense a differential pressure across the variable area flow orifice and supply a differential pressure signal;

an upstream conduit having an inlet coupled to the passageway upstream of the variable area flow orifice and an outlet coupled to the differential pressure sensor;

a downstream conduit having an inlet coupled to the passageway downstream of the variable area flow orifice and an outlet coupled to the differential pressure sensor;

a flow venturi coupled to the downstream conduit inlet and positioned proximate the variable area flow orifice; and

a processor coupled to receive the differential pressure signal and operable to determine the fluid flow parameter in the passageway therefrom.

27. A method of determining a fluid flow parameter in a passageway having a variable area flow orifice, comprising:

determining differential pressure across the variable area flow orifice;

determining fluid pressure upstream of the variable area flow orifice;

determining fluid temperature in the duct;

determining a position of the variable area flow orifice; and

determining the fluid flow rate parameter in the passageway based on the measured differential pressure, the measured upstream fluid pressure, the measured fluid temperature, and the determined valve position.

28. The method of claim 27, wherein the step of determining the fluid flow parameter comprises:

determining a pressure ratio of downstream pressure to upstream pressure based on the determined differential pressure and the determined upstream pressure;

determining a corrected flow rate based on the determined pressure ratio and the determined valve position;

determining the fluid flow rate based on the corrected flow rate and the measured temperature and measured upstream pressure.

29. The method of claim 28, wherein the step of determining the fluid flow parameter, further comprises:

determining a ratio of the measured temperature to a standard temperature value to obtain a temperature correction value;

determining a ratio of the measured upstream pressure to a standard pressure value to obtain a pressure correction value;

determining a ratio of the temperature correction value to the pressure correction value to obtain a pressure-temperature correction value; and

multiplying the uncorrected fluid flow rate by the pressure temperature correction value.

30. The method of claim 28, wherein the step of measuring the differential pressure across the variable area flow orifice comprises:

coupling an inlet of an upstream conduit to the passageway upstream of the variable area flow orifice and coupling an outlet of the upstream conduit to a differential pressure sensor;

coupling an inlet of a downstream conduit to the passageway downstream of the variable area flow orifice and coupling an outlet of the downstream conduit to the differential pressure sensor; and

coupling a flow venturi to the inlet of the downstream conduit and positioning the flow venturi proximate the variable area flow orifice.

31. The method of claim 28, wherein the fluid temperature is sensed upstream of the variable area flow orifice.

32. The valve of claim 28, wherein the fluid temperature is sensed downstream of the variable area flow orifice.