Fluid regulator with integrated rapid pressurization bypass valve

• US 9,157,540 B2
• Filed: 01/28/2013
• Issued: 10/13/2015
• Est. Priority Date: 01/28/2013
• Status: Active Grant

• Current Assignee: Tescom Corporation (Emerson Electric Company)
• Original Assignee: Tescom Corporation (Emerson Electric Company)
• Inventors: Larsen, Todd William, Kirchner, Chad Ray, Muir, Gordon Cameron
• Primary Examiner(s): CAHILL, JESSICA MARIE
• Application Number:
  US13/751,904
• Publication Number:
  US 20140209178A1
• Time in Patent Office: 988 Days
• US Class Current: 1/1
• CPC Class Codes: F16K 17/00 Safety valves; Equalising valves, e.g. pressure relief valves
• CPC Class Codes: G05D 16/0404 with two or more controllers mounted in parallel
• CPC Class Codes: G05D 16/107 with a spring-loaded piston in combination with a spring-loaded slideable obturator that move together over range of motion during normal operation
• CPC Class Codes: G05D 7/0133 within the flow-path
• CPC Class Codes: Y10T 137/0368 By speed of fluid
• CPC Class Codes: Y10T 137/7759 Responsive to change in rate of fluid flow
• CPC Class Codes: Y10T 137/8733 Fluid pressure regulator in at least one branch

Abstract

A fluid flow control device includes a regulator for operating at high pressures and an integral bypass valve. The regulator and the bypass valve each include a control assembly that is movable between an open position and a closed position. The regulator and bypass valves are biased into the open positions and adapted to move into the closed positions when an operating pressure rises to above respective regulator and bypass set-point pressures. The bypass set-point pressure is lower than the regulator set-point pressure such that when the operating pressure rises above the bypass set-point pressure, the bypass valve automatically closes and allows the regulator to perform under normal operating conditions. So configured, the bypass valve is arranged to accommodate at least some of the fluid flow through the system until the operating pressure reaches the normal operating pressure, which is somewhere between the bypass and regulator set-point pressures.

Claims

1. A fluid flow control device, comprising:

a valve body defining an inlet, an outlet, a gallery disposed between the inlet and the outlet, a regulator cavity disposed between the gallery and the outlet, and a bypass cavity disposed between the gallery and the outlet;

a regulator flow path extending between the inlet and the outlet of the valve body via the gallery and the regulator cavity, the regulator flow path having a first effective cross-sectional area;

a bypass flow path extending between the inlet and the outlet of the valve body via the gallery and the bypass cavity, the bypass flow path having a second effective cross-sectional area that is greater than the first effective cross-sectional area;

a bypass valve connected to the valve body and including a bypass control assembly, the bypass control assembly including a bypass control element and a bypass biasing device, the bypass control element being movable relative to the bypass cavity of the valve body between an open position allowing fluid flow through the bypass flow path and a closed position preventing fluid flow through the bypass flow path, the bypass biasing device urging the bypass control element toward the open position such that the bypass control element only occupies the closed position when a fluid pressure in the bypass cavity is equal to or greater than a bypass set-point pressure; and

a regulator connected to the valve body and including a regulator control assembly, the regulator control assembly including a regulator control element and a regulator biasing device, the regulator control element being movable relative to the regulator cavity of the valve body between an open position, which does not prevent fluid from flowing through the regulator flow path, and a closed position, which does prevent fluid from flowing through the regulator flow path, the regulator biasing device urging the regulator control element toward the open position such that the regulator control element occupies the open position until a fluid pressure in the regulator cavity of the valve body is equal to or greater than a regulator set-point pressure,

wherein the regulator set-point pressure is greater than the bypass set-point pressure.

2. The device of claim 1, wherein the valve body comprises a single piece of material defining the inlet, the outlet, the gallery, the regulator cavity, and the bypass cavity.

3. The device of claim 1, wherein a ratio of the second effective cross-sectional area to the first effective cross-sectional area is in a range of approximately 10:

1 to approximately 500;

1.

4. The device of claim 1, wherein a ratio of the second effective cross-sectional area to the first effective cross-sectional area is in a range of approximately 50:

1 to approximately 300;

1.

5. The device of claim 1, wherein the bypass valve further comprises an override lock that is movable between a locked position engaging and restraining the bypass control element in the closed position and an unlocked position allowing the bypass control element to freely move between the opened and closed positions.

6. The device of claim 1, wherein the valve body further defines an aperture disposed between the gallery and the regulator cavity and the device further comprises a biased valve member disposed in at least one of the regulator cavity and the gallery, the biased valve member occupying a closed position in engagement with the aperture and preventing fluid flow through the regulator flow path when the bypass control element is in the open position and occupying an open position displaced from engagement with the aperture when the bypass control element is in the closed position.

7. The device of claim 1, wherein the valve body further defines a seating orifice adjacent to the bypass cavity, the seating orifice adapted to be engaged by the bypass control element when the bypass control element is in the closed position.

8. The device of claim 7, wherein the bypass valve further comprises a bypass dome removably connected to the valve body adjacent to the bypass cavity such that that the bypass control element and the bypass biasing device are disposed between the bypass dome and the seating orifice of the valve body.

9. The device of claim 8, wherein the bypass control element further comprises a sensing surface disposed adjacent to the bypass dome and a sensing bore extending through the bypass control element, the sensing bore providing fluid communication between the gallery of the valve body and the sensing surface at least when the bypass control element is in the open position.

10. The device of claim 9, wherein the bypass biasing device comprises a coil spring biasing the bypass control element away from the seating orifice and toward the bypass dome.

11. A fluid flow control device, comprising:

a valve body defining an inlet, an outlet, a gallery disposed between the inlet and the outlet, a regulator cavity disposed between the gallery and the outlet, a bypass cavity disposed between the gallery and the outlet, and a seating orifice disposed in the bypass cavity;

a regulator flow path extending between the inlet and the outlet of the valve body via the gallery and the regulator cavity;

a bypass flow path extending between the inlet and the outlet of the valve body via the gallery and the bypass cavity;

a regulator connected to the valve body for controlling the flow of fluid along the regulator flow path, the regulator including a regulator control assembly configured to occupy an open position, which does not prevent fluid from flowing through the regulator flow path, and a closed position, which does prevent fluid from flowing through the regulator flow path, the regulator control assembly further being biased into the open position such that the regulator control assembly occupies the open position until a fluid pressure in the gallery sensed by the regulator is equal to or greater than a regulator set-point pressure; and

a bypass valve connected to the valve body and including a bypass dome, a bypass control element, and a bypass biasing device, the bypass dome removably connected to the valve body adjacent to the bypass cavity, the bypass control element slidably disposed in the bypass cavity and including a first end defining a seating surface disposed adjacent to the seating orifice and a second end defining a sensing surface disposed adjacent to the bypass dome, the bypass biasing device disposed between the bypass control element and the seating orifice,

the bypass control element being movable between an open position, wherein the seating surface is spaced away from the seating orifice, and a closed position, wherein the seating surface engages the seating orifice, the bypass biasing device urging the bypass control element toward the open position such that the bypass control element occupies the open position until a fluid pressure in the gallery sensed by the sensing surface of the bypass control element is equal to or greater than a bypass set-point pressure,

wherein the bypass set-point pressure is less than the regulator set-point pressure.

12. The device of claim 11, wherein the valve body comprises a single piece of material defining the inlet, the outlet, the gallery, the regulator cavity, the bypass cavity, and the seating orifice.

13. The device of claim 11, wherein the bypass control element further comprises a sensing bore extending through the bypass control element from the first end to the second end, the sensing bore providing fluid communication between the gallery of the valve body and the sensing surface of the bypass control element when the bypass control element is in the open position.

14. The device of claim 11, further comprising a spacer fixed in the bypass cavity between the bypass biasing device and the seating orifice and defining a guide bore through which the bypass control element is slidably disposed.

15. The device of claim 11, wherein the bypass biasing device comprises a coil spring.

16. The device of claim 11, wherein the bypass valve further comprises an override lock that is movable between a locked position engaging and restraining the bypass control element in the closed position and an unlocked position allowing the bypass control element to freely move between the opened and closed positions.

17. The device of claim 11, wherein the valve body further defines an aperture disposed between the gallery and the regulator cavity and the regulator further comprises a biased valve member disposed in at least one of the regulator cavity and the gallery, the biased valve member occupying a closed position in engagement with the aperture and preventing fluid flow through the regulator flow path when the bypass control element is in the open position and occupying an open position displaced from engagement with the aperture when the bypass control element is in the closed position.

18. The device of claim 11, wherein the regulator flow path has a first effective cross-sectional area and the bypass flow path has a second effective cross-sectional area that is greater than the first effective cross-sectional area.

19. The device of claim 18, wherein a ratio of the second effective cross-sectional area to the first effective cross-sectional area is in a range of approximately 10:

1 to approximately 500;

1.

20. The device of claim 18, wherein a ratio of the second effective cross-sectional area to the first effective cross-sectional area is in a range of approximately 50:

1 to approximately 300;

1.