U.S. patent application number 12/062946 was filed with the patent office on 2008-10-16 for system and method for hydraulically managing fluid pressure downstream from a main valve.
This patent application is currently assigned to CLA-VAL CO.. Invention is credited to Robert Folk.
Application Number | 20080251130 12/062946 |
Document ID | / |
Family ID | 39864617 |
Filed Date | 2008-10-16 |
United States Patent
Application |
20080251130 |
Kind Code |
A1 |
Folk; Robert |
October 16, 2008 |
SYSTEM AND METHOD FOR HYDRAULICALLY MANAGING FLUID PRESSURE
DOWNSTREAM FROM A MAIN VALVE
Abstract
A system and method for controlling fluid pressure downstream a
main valve includes associating a variable orifice with the main
valve such that the variable orifice opens as the main valve is
opened and closes as the main valve is closed. A fluid stream taken
from a fluid inlet of the main valve is passed to an inlet of the
variable orifice. A fixed orifice is in fluid communication with an
outlet of the variable orifice. A pressure differential between the
inlet and outlet of a fixed orifice is detected by a control pilot
device, which hydraulically opens or closes the main valve in
response to the detected fixed orifice pressure differential
between low pressure and high pressure set points.
Inventors: |
Folk; Robert; (Costa Mesa,
CA) |
Correspondence
Address: |
KELLY LOWRY & KELLEY, LLP
6320 CANOGA AVENUE, SUITE 1650
WOODLAND HILLS
CA
91367
US
|
Assignee: |
CLA-VAL CO.
Costa Mesa
CA
|
Family ID: |
39864617 |
Appl. No.: |
12/062946 |
Filed: |
April 4, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11927474 |
Oct 29, 2007 |
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12062946 |
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60911604 |
Apr 13, 2007 |
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Current U.S.
Class: |
137/14 ;
137/489.5; 137/624.27 |
Current CPC
Class: |
Y10T 137/86485 20150401;
Y10T 137/7762 20150401; Y10T 137/7797 20150401; G05D 16/163
20130101; Y10T 137/7768 20150401; F16K 31/365 20130101; Y10T
137/0396 20150401; Y10T 137/0379 20150401; Y10T 137/7828 20150401;
Y10T 137/7764 20150401 |
Class at
Publication: |
137/14 ;
137/624.27; 137/489.5 |
International
Class: |
F17D 1/00 20060101
F17D001/00; F16K 31/00 20060101 F16K031/00; F16K 31/36 20060101
F16K031/36 |
Claims
1. A method of controlling fluid pressure downstream a main valve,
comprising the steps of: providing a main valve having a fluid
inlet and a fluid outlet, the main valve being configured to open
to increase fluid flow therethrough, and close to reduce fluid flow
therethrough; associating a variable orifice with the main valve
such that the flow area of the variable orifice changes as the main
valve position changes; passing a fluid stream, having a pressure
substantially matching a fluid inlet pressure of the main valve, to
an inlet of the variable orifice; placing an inlet of a fixed
orifice in fluid communication with an outlet of the variable
orifice; detecting a pressure differential between the inlet and
outlet of the fixed orifice; and opening or closing the main valve
in response to the detected fixed orifice pressure
differential.
2. The method of claim 1, wherein the opening or closing the main
valve step includes the step of hydraulically opening or closing
the main valve.
3. The method of claim 1, including the step of using a control
pilot valve apparatus in fluid communication with the variable
orifice, the fixed orifice, and the main valve to detect the
pressure differential between the inlet and outlet of the fixed
orifice and open or close the main valve.
4. The method of claim 3, including the steps of: passing a first
portion of the fluid stream exiting the outlet of the variable
orifice to a first chamber of a low pressure control chamber of the
pilot valve apparatus; passing a second portion of the fluid stream
exiting from the outlet of the fixed orifice to a second chamber of
the low pressure control chamber of the pilot valve apparatus, the
first and second chambers having a first flexible diaphragm
therebetween; generating a second fluid stream having a pressure
substantially equal to the fluid inlet pressure of the main valve;
passing a first portion of the second stream to a first chamber of
a high pressure chamber of the control pilot valve apparatus at
least partially defined by a second flexible diaphragm, through a
variable valve, into a second chamber, and outlet of the high
pressure chamber; passing a second portion of the second stream to
a hydraulic control chamber of the main valve; opening or closing
the variable valve of the high pressure chamber in response to
detected pressures within the high pressure chamber and the low
pressure chamber; and hydraulically opening the main valve by
lessening the second portion of the second stream as the variable
valve of the high pressure chamber is opened, and hydraulically
closing the main valve by increasing the second portion of the
second stream as the variable valve of the high pressure chamber is
closed.
5. The method of claim 4, wherein the opening or closing of the
variable valve of the pilot valve apparatus includes the step of
moving a stem connected to the first flexible diaphragm into
contact with a movable poppet of the variable valve.
6. The method of claim 1, including the step of passing the fluid
stream through a pressure regulator passageway before passing the
fluid stream through the variable orifice.
7. The method of claim 6, including the step of adjusting the
pressure regulator passageway in order to modify a downstream flow
pressure regulation profile.
8. The method of claim 4, including the step of setting an upper
pressure set point and a lower pressure set point.
9. The method of claim 8, wherein the setting of a lower pressure
set point step includes the step of selectively limiting a range of
travel of the first flexible diaphragm.
10. The method of claim 8, wherein the setting an upper pressure
set point step includes the step of selectively limiting a range of
travel of the second flexible diaphragm.
11. A system for hydraulically managing fluid pressure downstream
of a main valve, comprising: a main valve having a fluid inlet and
a fluid outlet, the main valve being configured to open to increase
fluid flow therethrough, and to close to reduce fluid flow
therethrough; a variable orifice assembly coupled to the main valve
such that the flow area of the variable orifice changes as the main
valve position changes; a fixed orifice in fluid communication with
an outlet of the variable orifice; and a control device operably
associated with the main valve, an inlet of the fixed orifice and
an outlet of the fixed orifice and configured to detect pressure
differentials between the inlet and outlet of the fixed orifice and
open and close the main valve in response to the detected pressure
differentials.
12. The system of claim 11, wherein the main valve comprises a main
valve body defining the fluid inlet and the fluid outlet, a main
valve seat disposed between the fluid inlet and the fluid outlet, a
main valve member movable between an open position away from the
main valve seat and a closed position engaging the main valve seat,
and a main valve diaphragm coupled to the main valve member, the
main valve diaphragm and the main valve body, or a cover thereof,
defining a control chamber.
13. The system of claim 12, wherein the control device is fluidly
coupled to the control chamber of the main valve so as to
hydraulically open and close the main valve member.
14. The system of claim 13, wherein the control device comprises a
control pilot valve apparatus having a high pressure regulating
chamber in fluid communication with the inlet of the main valve and
the main valve control chamber, and low pressure regulating
chambers in fluid communication with the outlet of the variable
orifice and the outlet of the fixed orifice.
15. The system of claim 14, wherein the low pressure regulating
chambers are separated by a flexible diaphragm supporting an
elongated stem.
16. The system of claim 14, wherein the high pressure regulating
chamber is at least partially defined by a second flexible
diaphragm, and includes a fluid flow passageway.
17. The system of claim 16, including a movable poppet extending
from the second flexible diaphragm and into the fluid flow
passageway of the high pressure regulating chamber.
18. The system of claim 17, wherein, depending on the pressures
within the chambers of the control pilot valve apparatus, the stem
is moved into engagement with the poppet, or the second flexible
diaphragm moves the poppet to alter the flow through the passageway
of the high pressure regulating chamber, resulting in an alteration
of hydraulic pressure in the control chamber of the main valve so
as to open or close the main valve.
19. The system of claim 17, including an atmospheric chamber
disposed between the high and low pressure regulating chambers, the
poppet extending into a first end of the atmospheric chamber and
the stem extending into a generally opposite end of the atmospheric
chamber.
20. The system of claim 12, wherein the variable orifice assembly
comprises a housing having a fluid inlet in fluid communication
with the main valve inlet, a fluid outlet in fluid communication
with the fixed orifice and the control device, and a stem slidably
disposed within the housing and coupled to the main valve
member.
21. The system of claim 20, wherein the stem and housing
cooperatively define the variable orifice between the inlet and the
outlet of the housing.
22. The system of claim 20, including a sleeve disposed between the
stem and the housing and having an aperture therethrough, the
sleeve, stem and housing cooperatively forming the variable
orifice.
23. The system of claim 22, wherein the sleeve is adjustably
positioned within the housing to vary the fluid flow from the
housing inlet to the housing outlet.
24. The system of claim 11, including a pressure regulator
apparatus having an inlet fluidly coupled to an inlet of the main
valve an inlet and an outlet fluidly coupled to an inlet of the
variable orifice assembly, the pressure regulator apparatus having
a selectively adjustable fluid passageway disposed between the
inlet and outlet thereof.
25. A control pilot valve apparatus, comprising: a housing; a fluid
low pressure regulating chamber disposed within the housing, and
divided into first and second sub-chambers, each having a fluid
inlet, by a first flexible diaphragm; a fluid high pressure
regulating chamber disposed within the housing, including a fluid
passageway intermediate an inlet and an outlet thereof, and at
least partially defined by a second flexible diaphragm; an
atmospheric chamber disposed between the fluid low pressure
regulating chamber and the fluid high pressure regulating chamber;
a poppet slidably disposed within the atmospheric chamber; and a
stem extending from the first flexible diaphragm into the
atmospheric chamber and movable into contact with the poppet;
wherein movement of the poppet by either the stem or the second
flexible diaphragm due to fluid pressure variations in the high
fluid pressure regulating chamber or the low pressure regulating
chamber varies fluid flow between the inlet and the outlet of the
fluid high pressure regulating chamber.
26. The apparatus of claim 25, wherein the first flexible diaphragm
is selectively biased with a first spring.
27. The apparatus of claim 26, wherein the bias of the first spring
is selectively adjustable to limit the movement of the stem to a
selected range defining a lower pressure set point.
28. The apparatus of claim 25, wherein the second flexible
diaphragm is selectively biased with a second spring.
29. The apparatus of claim 28, wherein the bias of the second
spring is selectively adjustable to limit the movement of the
poppet to a selected range defining an upper pressure set point.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention generally relates to automatic valves,
such as those employed on municipal water utility systems. More
particularly, the present invention relates to a hydraulically
adjustable pressure management control valve designed to control
pressure downstream of a main valve.
[0002] There is a general understanding throughout the worldwide
water supply industry that instances of water loss are common in
many water distribution networks and in many instances the level of
water loss can be relatively high. The amount of water loss in the
system is due to a variety of leak sources, such as improperly
tightened pipe flange connections, leaking flange gaskets, leaking
valve seals, failed seals, old pipes (with pinhole bursts), loose
fittings, leaky faucets, etc. The sum of these sources of leakage
can add up to a substantial amount of water loss. Maintaining the
entry point pressure at all times at the level necessary to provide
adequate pressure at the distant points for periods of high demand
can result, during periods of low demand, in excessive pressure at
the consumer's premises, and thus increased waste of water by
unnecessary consumption and leakage. The volume of water lost
through leakage is directly related to pressure in the system.
[0003] Automatic pressure reducing valves are used in water
distribution systems to reduce pressure to a pre-determined value
or sub-point that is adequate, but does not expose normal
components, such as household hot water tanks, to overpressure. The
sub-point is typically determined to provide minimum pressure that
meets criteria of the water utility, particularly under maximum or
"peak" demand conditions which can occur when a fire is being
fought. The pressure required for peak demand is usually
significantly higher than that required for "off-peak" or typical
nighttime conditions. Under low demand conditions, not only does
leakage form a higher proportion of the total demand, but
investigation has implied that some leak orifices can actually
increase in area with pressure, aggravating the problem if
excessive pressures are maintained at all times.
[0004] Various attempts have been previously made to reduce such
losses by introducing a degree of control over the supply pressure
in response to demand. One known system uses electrical circuit
means with pressure and flow-rate sensors from monitoring pressure
and flow-rate and then processing the information obtained and
using it in turn to control suitable electrically operated valve
means. Such systems are, however, relatively complex and expensive
and require a continuous external power supply giving rise to
additional capital and running costs and reliability problems.
[0005] There also exist flow-driven valves which use fluid
pressures to control actuation of the main valve, and thus are
independent of external power sources and can be used in
essentially any location. One such flow-driven valve system is
disclosed in U.S. Pat. No. 5,967,176 to Blann, et al. The system
controls high and low pressures by utilizing the pressure drop
across an orifice plate that is installed in the main line, usually
attached directly to the inlet or outlet flange of the main valve.
The pressure control is independent of the main valve position, and
is a direct function of system flow. The pressure control device
monitors the pressure drop or flow across the orifice plate.
Control pressure is varied based upon the movement of a pilot valve
member with respect to a fixed pilot valve member, which in turn
controls the main control valve.
[0006] However, this system has many shortcomings. The diameter of
the orifice plate may need to be customized for different high/low
flow applications. For example, a smaller orifice diameter may be
required if flows are not sufficient to develop the required
pressure drop across the system orifice. Likewise, the system
orifice may need to be increased if pressure drops are too large
because a smaller orifice can limit the flow capacity of the
system. The orifice plate also decreases the capacity of the main
valve. This is particularly a concern when high flow is necessary,
such as a high flow of water to fight a fire or the like. The added
orifice plate limits the capacity of the main valve for fire flow
situations. Moreover, it is difficult to retrofit existing valves
with this system as the flange spacing must be modified to
accommodate the orifice plate, typically requiring removal of the
main valve from the line.
[0007] Accordingly, there is a continuing need for an improved
flow-driven valve system for automatically controlling downstream
pressure between selected set points. The present invention
fulfills these needs and provides other related advantages.
SUMMARY OF THE INVENTION
[0008] The present invention resides in a system and method for
hydraulically managing fluid pressure downstream a main valve. As
will be more fully described herein, the system is flow-driven and
responds to changing flow demand downstream from a main valve, so
as to manage and control the fluid pressure downstream from the
main valve between predetermined set points.
[0009] The system generally comprises a main valve having a main
valve body defining a fluid inlet and a fluid outlet. A main valve
seat is disposed between the fluid inlet and the fluid outlet. A
main valve member is movable between an open position away from the
main valve seat, and a closed position engaging the main valve
seat. The main valve is configured to hydraulically open to
increase fluid flow therethrough, and hydraulically close to reduce
fluid flow therethrough. A main valve diaphragm is coupled to the
main valve member. The main valve diaphragm and the main valve
body, or a cover thereof, define a control chamber having a control
port in fluid communication with a pilot control device.
[0010] A variable orifice assembly is coupled to the main valve so
as to open a variable orifice thereof as the main valve is opened,
and close the variable orifice as the main valve is closed. A fixed
orifice is in fluid communication with an outlet of the variable
orifice. A control device is operably associated with the main
valve, an inlet of the fixed orifice and an outlet of the fixed
orifice, and configured to detect pressure differentials between
the inlet and the outlet of the fixed orifice and open and close
the main valve in response to the detected pressure differentials.
The control device is fluidly coupled to the control chamber of the
main valve, so as to hydraulically open and close the main valve
member.
[0011] The variable orifice assembly comprises a housing having a
fluid inlet in fluid communication with the main valve inlet. A
fluid outlet of the variable orifice assembly is in fluid
communication with the fixed orifice and a control device. A stem
is slidably disposed within the housing and coupled, or engagable
with, the main valve member. The stem and housing cooperatively
define the variable orifice between the inlet and outlet of the
housing of the variable orifice assembly. A sleeve may be disposed
between the stem and the housing, having an aperture therethrough,
the sleeve, stem and housing cooperatively forming the variable
orifice. The sleeve may be adjustably positioned within the housing
to vary the fluid flow from the housing inlet to the housing
outlet.
[0012] The control device typically comprises a control pilot valve
apparatus having a high pressure regulating chamber in fluid
communication with the inlet of the main valve as well as the main
valve control chamber. The control pilot valve apparatus also has
low pressure regulating chambers in fluid communication with the
outlet of the variable orifice and the outlet of the fixed orifice.
The low pressure regulating chambers are separated by a flexible
diaphragm supporting an elongated stem. The high pressure
regulating chamber is at least partially defined by a second
flexible diaphragm, and includes a fluid flow passageway
therethrough. A moveable poppet extends from the second flexible
diaphragm and into the fluid flow passageway of the high pressure
regulating chamber. The poppet extends into a first end of the
atmospheric chamber, and the stem extends into a generally opposite
end of the atmospheric chamber.
[0013] Depending upon the pressures within the chambers of the
control pilot valve apparatus, the stem is moved into engagement
with the poppet, or the second flexible diaphragm moves the poppet,
to alter the flow through the passageway of the high pressure
regulating chamber. This results in an alteration of hydraulic
pressure in the control chamber of the main valve so as to open or
close the main valve. In a particularly preferred embodiment, an
atmospheric chamber is disposed between the high and low pressure
regulating chambers.
[0014] In a particularly preferred embodiment, the control pilot
valve apparatus comprises a housing having a fluid low pressure
regulating chamber disposed therein. The fluid low pressure
regulating chamber is divided into first and second sub-chambers by
a first flexible diaphragm. Each sub-chamber has a fluid inlet. A
fluid high pressure regulating chamber is disposed within the
housing, and includes a fluid passageway intermediate an inlet and
an outlet thereof. The fluid high pressure regulating chamber is at
least partially defined by a second flexible diaphragm. An
atmospheric chamber is disposed between the fluid low pressure
regulating chamber and the fluid high pressure regulating chamber.
A poppet is slidably disposed within the atmospheric chamber. A
stem extends from the first flexible diaphragm into the atmospheric
chamber and is movable into contact with the poppet. Movement of
the poppet by either the stem, or the second flexible diaphragm,
due to fluid pressure variations in the high fluid pressure
regulating chamber or the low pressure regulating chamber varies
fluid flow between the inlet and outlet of the fluid high pressure
regulating chamber. This alters the fluid pressure in the control
chamber of the main valve, so as to hydraulically open or close the
main valve member.
[0015] The first flexible diaphragm is selectively biased with a
first spring. The first spring is selectively adjustable to limit
the movement of the stem to a selected range defining a lower
pressure set point. Similarly, the second flexible diaphragm is
selectively biased with the second spring. The second spring is
selectively adjustable to limit the movement of the poppet to a
selected range defining an upper pressure set point.
[0016] A pressure regulator apparatus may be disposed between the
fluid conduit inlet and the fluid inlet of the variable orifice
assembly to customize and regulate the pressure entering into the
variable orifice assembly. The pressure regulator comprises a
housing having a fluid inlet and a fluid outlet. A selectively
adjustable fluid passageway is disposed between the fluid inlet and
fluid outlet.
[0017] In accordance with the present invention, a method for
controlling fluid pressure downstream a main valve comprises the
steps of providing a main valve having a fluid inlet and a fluid
outlet. The main valve is configured to open to increase fluid flow
therethrough, and close to reduce fluid flow therethrough. A
variable orifice is associated with the main valve such that the
variable orifice opens as the main valve is opened and closes as
the main valve is closed. A fluid stream, having a pressure
substantially matching a fluid inlet pressure of the main valve, is
passed to an inlet of the variable orifice. An inlet of a fixed
orifice is placed in fluid communication with an outlet of the
variable orifice. A pressure differential between the inlet and
outlet of the fixed orifice is detected, and the main valve is
opened or closed in response to the detected fixed orifice pressure
differential.
[0018] In a particularly preferred embodiment, the main valve is
opened or closed hydraulically. This is done by means of a control
pilot valve apparatus in fluid communication with the variable
orifice, the fixed orifice, and the main valve. The control pilot
valve apparatus detects the pressure differential between the inlet
and outlet of the fixed orifice, and hydraulically opens or closes
the main valve.
[0019] In one embodiment, a first portion of the fluid stream
exiting the outlet of the variable orifice is passed to a first
chamber of a low pressure control chamber of the pilot valve
apparatus. A second portion of the fluid stream exiting from the
outlet of the fixed orifice is passed to a second chamber of the
low pressure control chamber of the pilot valve apparatus. The
first and second chambers have a first flexible diaphragm
therebetween.
[0020] A second fluid stream is generated which has a pressure
substantially equal to the fluid inlet pressure of the main valve.
A first portion of the second stream is passed through a first
chamber of a high pressure chamber of the control pilot valve
apparatus, which is at least partially defined by a second flexible
diaphragm. The first portion of the second stream is passed through
a variable valve, into a second chamber and subsequently an outlet
of the high pressure chamber. A second portion of the second stream
is passed through a hydraulic control chamber of the main
valve.
[0021] The variable valve of the high pressure chamber is opened or
closed in response to detected pressures within the high pressure
chamber and low pressure chamber. The main valve is hydraulically
opened by lessening the second portion of the second stream as the
variable valve of the high pressure chamber is opened. The main
valve is hydraulically closed by increasing the second portion of
the second stream as the variable valve of the high pressure
chamber is closed.
[0022] An upper pressure set point and a lower pressure set point
are set. The lower pressure set point is set by selectively
limiting a range of travel of the first flexible diaphragm. An
upper pressure set point is set by selectively limiting a range of
travel of the second flexible diaphragm.
[0023] Other features and advantages of the present invention will
become apparent from the following more detailed description, taken
in conjunction with the accompanying drawings, which illustrate, by
way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The accompanying drawings illustrate the invention. In such
drawings:
[0025] FIG. 1 is a schematic illustration of a system in a high
fluid flow state for hydraulically managing fluid pressure
downstream of a main valve between selected set points, in
accordance with the present invention;
[0026] FIG. 2 is a cross-sectional view of a main valve and a
variable orifice assembly positioned in a high flow state, in
accordance with the present invention;
[0027] FIG. 3 is an enlarged cross-sectional view of area "3" of
FIG. 2, illustrating a variable orifice thereof in an open
position;
[0028] FIG. 4 is a cross-sectional view of an alternative variable
orifice assembly embodying the present invention;
[0029] FIG. 5 is an enlarged cross-sectional view taken generally
along area "5" of FIG. 4, illustrating the variable orifice in an
open position;
[0030] FIG. 6 is a cross-sectional view of a control pilot valve
apparatus used in accordance with the present invention, in a high
flow state;
[0031] FIG. 7 is a cross-sectional view of a pressure regulator
apparatus used in accordance with the present invention;
[0032] FIG. 8 is a diagram illustrating pressure profiles created
by modifying the variable orifice assembly and implementing the
pressure regulator apparatus;
[0033] FIG. 9 is a cross-sectional view of the control pilot valve
apparatus in a high pressure state;
[0034] FIG. 10 is a schematic illustration of the system of the
present invention in a low flow state;
[0035] FIG. 11 is a cross-sectional view of the main valve and
variable orifice assembly in the low flow state;
[0036] FIG. 12 is an enlarged cross-sectional view of area "12" of
FIG. 11, illustrating a variable orifice thereof in a closed
position;
[0037] FIG. 13 is a cross-sectional view of the variable orifice
assembly of FIG. 4, but illustrating the variable orifice in a
closed position;
[0038] FIG. 14 is an enlarged cross-sectional view of area "14" of
FIG. 13;
[0039] FIG. 15 is a cross-sectional view similar to FIG. 13, but
illustrating a sleeve thereof moved into a different profile
position; and
[0040] FIG. 16 is a cross-sectional view of the control pilot valve
apparatus used in accordance with the present invention in a low
flow state.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0041] As shown in the accompanying drawings, for purposes of
illustration, the present invention is directed to an adjustable
hydraulically operated pressure management control valve system 10.
As will be more fully described herein, the system 10 of the
present invention is primarily intended for use in the waterworks
industry where there is a desire to reduce the amount of water loss
in the system due to leaks. The invention can reduce the amount of
water loss in a system by reducing the system pressure as the flow
or system demand decreases. A common example would be a residential
water system where water demand is high during the day and low at
night. If the pressure is lower during low usage, then a lower
pressure will result in lower water losses throughout the
system.
[0042] As will be more fully described herein, the system 10 of the
present invention comprises a main valve assembly 100 operably
coupled to a pilot control system 20. The pilot control system 20
includes a variable orifice assembly 200, a control device in the
form of a pilot valve apparatus 300, and an optional pressure
regulator apparatus 400. Various conduits 22-42 fluidly couple
these components and provide pressurized fluid streams, as will be
more fully described herein. The pilot control system 20
hydraulically opens the main valve assembly 100 during high demand
conditions, and closes the main valve assembly 100 during low
demand conditions, resulting in a reduction of the amount of water
loss in a waterworks system downstream of the main valve assembly
100.
[0043] With reference now to FIGS. 1 and 2, the main valve 100 is
comprised of a main valve body 102 defining an inlet 104 and an
outlet 106. Intermediate the main valve inlet and outlet 104 and
106 is a main valve seat 108. A main valve member is movable
between an open position away from the main valve seat 108, as
illustrated in FIG. 1, and a closed position engaging the main
valve seat 108. The main valve member 110 includes a movable stem
112 for guiding the main valve member 110 into and out of
engagement with the main valve seat 108. A spring 114 is typically
also implemented in facilitating and guiding the main valve member
110 movement. A main valve diaphragm 116 is coupled to the main
valve member 110 and extends between the main valve body 102 and a
cover 118 of the main valve 100 so as to define a fluid control
chamber 120 between the diaphragm 116 and the cover 118, or other
portion of the body 102. The control chamber includes an inlet port
122 for fluid coupling with the pilot control system 20, such as
through conduit 32.
[0044] As will be more fully explained herein, the pilot control
system 20 increases fluid flow into the control chamber 120 during
low flow or low demand situations, causing the main valve member
110 to move downwardly towards engagement with the main valve seat
108. Conversely, during high flow or high demand situations, less
fluid is directed into the fluid control chamber 120, resulting in
a lower pressure and enabling the main valve member 110 to move
away from the main valve seat 108 into an open position so as to
permit more fluid to flow through the main valve 100.
[0045] With reference again to FIG. 1, conduit 22 has an inlet 24
disposed upstream of the main valve seat 108 and main valve member
110, typically adjacent to the inlet 104 of the main valve assembly
100. A fluid stream having a pressure proportional to the fluid
stream at the inlet 104 of the main valve 100 is thus generated in
the conduit 22. A portion of the fluid stream is diverted into
conduit 26 and through the variable orifice assembly 200. As will
be more fully described below, the portion of the fluid stream
passing through conduit 26 may first pass through a pressure
regulator device 400 so as to control the profile of the pressure
regulation ramp and maintain pressure stability to the inlet 200
when regulating between low and high pressure set points.
[0046] With reference now to FIG. 2, in one embodiment the variable
orifice assembly 200 includes a housing 202 defining a fluid inlet
204 and a fluid outlet 206. Typically, the housing 202 is coupled
to the main valve cover 118, as illustrated. However, fluid
pressures within the variable orifice assembly housing 200 and the
main valve 100 are isolated from one another, such as by utilizing
an O-ring 208 in an adapter 210 which isolate the pressure within
the housing 202 and the main valve control chamber 120.
[0047] A stem 212 is movably disposed within the housing 202, and
engagable with the stem 112 of the main valve member 110. In this
manner, as the main valve member 110 moves up and down, the stem
212 of the variable orifice assembly 200 also moves up and down.
The housing 202 and the stem 212 cooperatively define a variable
orifice 214. For example, typically the stem 212 is at least
partially hollow and includes an aperture or slit therein. As
illustrated in FIG. 3, when the stem 212 is raised upwardly by the
stem 112, the variable orifice 214 is in fluid communication with
the outlet 206, such as by an intermediate chamber 216.
[0048] With reference now to FIG. 4, an alternative variable
orifice assembly 200' is shown which is capable of being adjusted
so as to customize a pressure regulation curve, between set points,
to set the application preferences of the user. In this embodiment,
the assembly 200' also includes a housing 202' which is connected
to the main valve member, typically the cover member 118, such as
by threaded connection 201'. A stem 212' is connected to the main
valve member stem 112, as discussed above, and includes an adapter
210' with an O-ring 208' to create a leak-free connection so as to
separate pressures therebetween. The housing 202' includes a fluid
inlet 204' and a fluid outlet 206'.
[0049] In this case, however, the stem is not hollow. Instead, the
housing 202' is adapted so as to receive a sleeve 203' between the
inner wall of the housing 202' and the stem 212'. As illustrated in
FIGS. 4 and 5, the sleeve 203' includes an aperture, typically in
the form of a slit 205', which is in fluid communication with an
intermediate chamber 216' of the housing 202', which is in fluid
communication with the outlet 206'. A section 207' of the stem is
configured so as to have a greater diameter towards an upper
portion thereof, or a shoulder which may include an O-ring or the
like, and be of reduced diameter, or include external passageways
or the like, in a lower portion thereof such that when the stem
212' is raised sufficiently, the reduced diameter profile of the
section 207' is in alignment with the slot 205' of the sleeve 203',
permitting fluid to flow from the housing inlet 204', around the
stem section 207', through the sleeve slot 205', into the
intermediary chamber 216', and out outlet 206'.
[0050] It will be readily appreciated by those skilled in the art
that the slot 205' can be created so as to create a pressure
regulation profile by increasing or decreasing the fluid flow
therethrough. Similarly, the exterior configuration of the stem
section 207' can be modified to correlate to increased or decreased
fluid flow. However, these techniques do not allow adjustment after
the assembly 200' has been manufactured and assembled.
[0051] Thus, with reference to FIGS. 4, 5 and 13, the sleeve 203'
is adjustably inserted and connected to the housing 202', such as
by threaded connection between the internal threads 209' and
external threads 211' of the housing 202' and sleeve 203',
respectively. This allows the sleeve 203' to be raised or lowered,
thus adjusting the position of the sleeve slot 205', and thus
requiring a greater or lesser stroke of the main valve stem 112 so
as to open or close the variable orifice between the variable
orifice assembly inlet 204' and outlet 206'.
[0052] The travel of the sleeve 203' may be limited, for example,
by the use of a set screw 213' which is disposed above a shoulder
215' of the sleeve 203'. Also, this serves as a precautionary
feature so as to not permit the user to inadvertently unthread the
sleeve 203' to the point where the variable orifice assembly 200'
does not function. It will be appreciated that the adjusting
position of the sleeve aperture 205' can be used to change or
customize the pressure curve profile between the low and high flow
set points of the system.
[0053] Those skilled in the art will appreciate that the foregoing
descriptions and illustrations for the variable orifice assembly
200 and 200' are preferred embodiments for illustration and
explanatory purposes. The important aspect of the variable orifice
assembly is that a variable orifice is created which varies in
relation to the stroke of the main valve member 110 such that as
the main valve member 110 is moved up and down, the variable
orifice is altered such that it opens and closes. The fluid output
of the variable orifice assembly drives a pressure differential
which is detected by a control device 300, typically a pilot
control apparatus, which limits and controls the opening and
closing of the main valve member 110.
[0054] With reference again to FIG. 1, when the stem 212 of the
variable orifice assembly 200 is raised, such as during high flow
or high demand situations, so as to open the variable orifice and
permit fluid to flow therethrough, the fluid passes into conduit 34
and is split such that a portion of the fluid is passed through a
fixed orifice device 50 through conduit 38 which is fluidly coupled
to the control pilot valve apparatus 300, and another portion is
passed through conduit 36 and into the control pilot valve
apparatus 300.
[0055] More particularly, with reference to FIG. 6, the control
pilot valve apparatus 300 includes a first, as illustrated an
upper, low pressure regulating chamber 302 and a second or lower
low pressure regulating chamber 304. These chambers 302 and 304 are
separated by a flexible diaphragm 306. The flexible diaphragm 306
extends across the housing 308 and divides the first and second low
pressure control chambers 302 and 304. A fluid inlet port 310
fluidly connects conduit 36, from the opening of the fixed orifice
50 or the outlet 206 of the variable orifice assembly 200 to the
first low pressure chamber 302. Inlet port 312 fluidly connects
conduit 38, from the outlet of the fixed orifice 50 to the second
or lower low pressure regulating chamber 304. It will be
appreciated by those skilled in the art that there can exist
pressure differentials between chambers 302 and 304, resulting in
the movement of the flexible diaphragm 306.
[0056] The control pilot valve apparatus 300 includes a low
pressure adjustment screw 312 threadedly connected to an end member
314. Typically, an O-ring 314 or the like is used to maintain a
fluid seal in the second pressure chamber 304. The end of the screw
312 engages a guide 318, supporting a spring 320. The spring is
contained within a piston 322 such that the spring 320 exerts a
force on the piston 322.
[0057] A stem 324 is connected to the piston 322, such as by use of
a nut 326 and a threaded end of the stem 324 extending into the
body of the piston 322. The stem 324 also extends through the
diaphragm 306 and a washer 328 disposed on a top surface of the
diaphragm 306. If any of these components are moved, such as due to
the force of the spring 320 or the fluid pressure differentials
between chambers 302 and 304, the connected members also move. With
reference to FIG. 6, it can be seen that a lower portion 330 of the
stem 324 is of an increased diameter with respect to an upper
portion 332 of the stem 324. The enlarged diameter of the lower
portion with respect to the upper portion allows the pressure force
in the first low pressure regulating chamber 302 to be greater than
the pressure force in the second low pressure regulating chamber
304.
[0058] With continuing reference to FIG. 6, it can also be seen
that the upper portion 332 of the stem 324 is at least partially
disposed within an atmospheric chamber 334, having a vent 336 to
the atmosphere. This atmospheric chamber 334 facilitates the
movement of the stem 324 therein, so as to come into contact with a
control poppet 338.
[0059] The control device 300, illustrated in a preferred
embodiment as a control pilot valve apparatus, includes a high
pressure regulating chamber 340 having an inlet port 342 and an
outlet port 344, defining a fluid passageway therethrough which is
opened and closed or constricted depending upon the position of the
control poppet 338.
[0060] A high pressure adjustment screw 346 threadedly extends
through an upper member 348 of the body. The end of the high
pressure adjustment screw 346 is in contact with an upper spring
guide 350 which acts upon an upper spring 352. The spring 352
extends between the upper guide 350 and a washer 354 coupled to an
upper, and typically smaller, diaphragm 356. The upper diaphragm
356 is disposed between the high pressure regulating chamber 340,
and a chamber 358 having atmospheric pressure with a vent 360 to
the atmosphere. The control poppet 338 has a threaded end which
extends through the upper flexible diaphragm 356 and washer or
retaining member 354, and is held in place and coupled to these
components by means of a nut 362. Thus, as the control poppet 338
is moved, the diaphragm 356 and spring 352 are also moved, and vice
versa.
[0061] With reference again to FIG. 1, a high demand or high flow
situation is illustrated. A fluid stream is generated through inlet
24, and passed through conduit 22. A portion of the stream is
passed through conduit 28, through fixed orifice device 52. From
there, this portion of the stream is fluidly coupled through
conduits 30 and 32 to inlet 342 of the control pilot valve
apparatus 300 and the control chamber 120 of the main valve 100.
Another portion of the fluid stream is directed through conduit 26
and into the inlet port 204 of the variable orifice assembly 200.
In the high flow/high demand situation, the main valve seat 110 is
opened and moved away from the valve seat 108. Thus, as the stem
112 of the main valve 100 is moved upwardly, the stem 212 of the
variable orifice assembly 200 is moved as well, exposing to an
increasing level the variable orifice 214 until the variable
orifice 214 presents a maximum passageway for fluid to flow
therethrough, out outlet 206, and into conduit 34.
[0062] The fluid stream exiting the variable orifice assembly 200
in conduit 34 passes through a fixed orifice device 50. Conduit 36
is fluidly coupled to the inlet of the fixed orifice device 50 and
the inlet port 310 of the first low pressure regulating chamber
302. Conduit 38 is fluidly connected to the outlet of the fixed
orifice device 50 and the inlet port 312 of the second low pressure
regulating chamber 304. As can be seen in FIG. 1, during high flow
conditions, there is an increased pressure P2 at the inlet of the
fixed orifice device 50 as compared to the pressure P3 at the
outlet of the fixed orifice device 50. This pressure differential
is detected within the control device 300, wherein the increased
pressure in the first low pressure regulating chamber 302 is higher
than the pressure in the second low pressure regulating chamber
304, causing the diaphragm 306 to move downwardly against the bias
of spring 320. This causes the stem 324 to move downwardly as well,
so as to be in spaced relation and out of contact with the control
poppet 338.
[0063] The bias of spring 352 moves the control poppet 338
downwardly, or into a fully open position such that the fluid flow
between inlet port 342 and outlet port 344 is at its greatest
flow.
[0064] Due to the relatively free flow of the fluid, as described
above, a relatively lesser amount of fluid and fluid pressure is
introduced into the control chamber 120 of the main valve 100,
permitting the main valve member 110 to be moved upwardly towards
the main valve cover 118. It will be noted that in this situation,
the pressure at P2 is greater than the pressure at P3 at the other
side of fixed orifice device 50. This is due to a relatively high
flow of fluid through variable orifice 214 and into the first low
pressure regulating chamber 302 of the control pilot valve
apparatus 300. Such would be the case, for example, when a large
flow is required downstream from the main valve assembly 100.
[0065] As explained above, the design of the present invention
controls high and low pressures by interacting with the variable
orifice 214 or the variable orifice assembly 200 operably coupled
to the main valve assembly 100. The variable orifice 214 opening
increases or decreases with the main valve member 110 stroke
upwardly or downwardly. The variable orifice 214 interacts with the
fixed orifice 50 in the control pilot system 20. As system demand
increases, the main valve 100 opens to respond to the increased
system demand. As the main valve 100 opens, the flow area through
the variable orifice 214 increases, which in turn increases the
pressure drop, or pressure differential, across the fixed orifice
device 50. The pressure drop, or differential, across this fixed
orifice 50 is used to control the transition of system downstream
pressure between the low and high pressure set points of the
control pilot valve apparatus 300.
[0066] In the illustrated design, the low pressure set point is set
and adjusted by turning screw 312, which serves to compress or
decompress spring 320, thus limiting the range of motion or travel
of the lower diaphragm 306 and stem 324. The upper or high pressure
adjustment is made by selectively turning screw 346, thus
compressing or decompressing spring 352, and thus affecting the
range of travel of the upper diaphragm 356 and the control poppet
338. Such adjustments set the low and high pressure set points of
the system 10.
[0067] The variable orifice 214 can be customized to control the
rate of change between the low and high pressure settings. If the
flow area through the variable orifice 214 is profiled to increase
quickly (relative to main valve member 110 stroke), the transition
between low and high pressure set points will likewise change
quickly. For example, for a variable orifice 214 where the flow
area through the variable orifice quickly changes, the transition
between the low pressure set point and the high pressure set point
would occur fairly quickly between the low and high flow conditions
resulting in a relatively steep curve between the low and high set
points. For instance, for a given valve size, such as an eight-inch
valve, pressure change could occur within a two hundred
gallon-per-minute flow span, or a relatively steep curve. However,
if the flow area through the variable orifice 214 is profiled to
increase slowly, relative to main valve member 110 stroke, then the
transition between the low and high pressure set points will
likewise change slowly. For example, a variable orifice 214 where
the flow area through the variable orifice slowly changes, then the
same low-high pressure transition would occur fairly slowly between
the low and high flow conditions. In this case, the change might
occur within a five hundred gallon-per-minute flow span, or a
relatively shallow curve. Changing the variable flow area geometry
of the variable orifice 214 can be used to change or customize the
pressure curve profile between the low and high flow set
points.
[0068] With reference now to FIGS. 1 and 7, as mentioned above,
fluid stream through conduit 26 may be passed through pressure
regulator apparatus 400 before being passed into the variable
orifice assembly 200. The pressure regulator apparatus 400 is
another means of customizing and controlling the rate of change
between the low and high pressure settings, so as to change or
customize the pressure curve profile between the low and high flow
set points. The pressure regulator apparatus generally comprises a
plug 402 connected to a seat assembly or body 404, and supporting a
disc retainer assembly 406. The body 404 defines an inlet 408 and
an outlet 410. A chamber or passageway 412 is disposed between the
inlet and outlet 408 and 410. A cover or upper body 414 defines a
chamber 416, typically exposed to atmosphere. A diaphragm 418 is
disposed between chambers 412 and 416. The diaphragm 418 is
operably connected or coupled to a spring 420 and a yoke 422. A
portion of the yoke defines a passageway 424 alignable with a
passageway of the inlet 408, so as to permit fluid to flow
therethrough. However, depending upon the position of the yoke 422,
the fluid is either allowed to pass through into passageway or
chamber 412, and out outlet 410, or is restricted or even closed
from passing into passageway or chamber 412.
[0069] The set point or adjustment is made by a screw 426 being
turned clockwise or counterclockwise, which applies a force to
spring guide 428, causing the spring 420 to be compressed or
relaxed. This impacts the position of diaphragm 418, and yoke 422.
This also establishes a range of travel for the diaphragm 418, if
any, so as to produce a relatively constant flow or pressure
through outlet 410, represented by P1 in FIG. 1. The pressure
regulator device 400 is used to control the pressure at P1. This in
turn customizes the profile of a pressure regulation ramp when
regulating between low and high pressure set points. When pressure
at P1 is equal to, or nearly equal to, the pressure at the main
valve inlet 104, then the pressure ramp is at its steepest. When
the pressure at P1 is appreciably lower than the main valve inlet
104 pressure, then the pressure ramp is shallower.
[0070] With reference now to FIG. 8, a diagram illustrates the
downstream pressure as compared to flow through the main valve 100.
Thus, when the P1 pressure equals the main valve inlet pressure
104, a relatively steep curve, shown by the solid line results.
When the pressure at P1 is less than the main valve inlet 104
pressure, illustrated by the dotted lines, a shallower curve or
profile is created. This occurs due to the use of the pressure
regulator apparatus 400. In FIG. 8, a pressure profile is
illustrated wherein the variable orifice 214 is modified
(illustrated by the dashed line). Including both the pressure
regulator apparatus 400 as well as modifying the variable orifice
214 results in a relatively shallow profile, illustrated by the
elongated dashed line.
[0071] Referring now to FIGS. 1 and 9, at some point during the
high flow or high demand situation, the pressure at P3 will begin
to increase, due to the pressure of the stream generated at inlet
42, and passed through conduit 40. In such a case, the pressure in
high pressure regulating chamber 340 of the control pilot valve
apparatus 300 will begin to increase. As the pressure in this
chamber 340 begins to increase, the upper diaphragm 356 will be
forced to move upwardly against the bias of spring 352, resulting
in the control poppet 338 being moved upwardly as well. The upward
movement of the control poppet 338 constricts the passageway and
fluid flow between the inlet port 342 and outlet 344 of the chamber
340.
[0072] With reference again to FIG. 1, in such a scenario when the
control poppet 338 is moved upwardly so as to constrict the fluid
flow through the high pressure chamber 340, a build-up in fluid
pressure begins to occur in conduits 30 and 32, which increases the
fluid pressure in control chamber 120, forcing the main valve
member 110 to close and move towards the main valve seat 108. This
in turn affects the fluid flow through the variable orifice
assembly 200, which will impact the pressure differential P2 and P3
across fixed orifice 50. Thus, the pressure and flow in the system
is controlled between the low pressure and high pressure set
points. As described above, adjustment screw 346 can be rotated so
as to relax or compress spring 352, increasing or decreasing the
range of potential motion in travel of the diaphragm 356 and the
control poppet 338. In this manner, the high pressure set point can
be adjusted and set to a predetermined level. Similarly, the set
screw 312 can be adjusted to compress or relax spring 320 so as to
adjust and set the low pressure set point to a predetermined level.
The upper spring 352 is used to set the system pressure for normal
or high flow conditions, and the lower spring 320 is used to set
the system pressure conditions for low flow conditions.
[0073] With reference to FIG. 10, the system 10 is illustrated in a
low flow or low demand state, wherein the main valve member 110 is
moved towards the main valve seat 108, so that fluid flow through
the main valve 100 is restricted, or there is a relatively low flow
through the main valve assembly 100.
[0074] With reference now to FIG. 11, in such a low flow or low
demand situation, the main valve member 110 moves towards its
closed position adjacent to main valve seat 108. Thus, variable
orifice assembly stem 212 is moved downwardly, occluding variable
passage 214, limiting or restricting, or even preventing, fluid
flow therethrough and out outlet 206. This can be seen in FIG.
12.
[0075] With reference now to FIGS. 13-15, in the alternative
embodiment of the variable orifice assembly 200', when the stem
212' is moved downwardly, section 207' is moved downwardly as well,
such that the wider diameter portion of the section 207' is in
contact with the sleeve 203', either reducing or preventing fluid
flow from the assembly inlet 204' and the sleeve slot 205', and
thus outlet 206'. It will be noted that the sleeve 203' has been
adjustably moved when comparing the variable valve orifice assembly
200' illustrated in FIGS. 13 and 15. As discussed above, movement
of the sleeve 203', either into or out of the housing 202', adjusts
the position of the sleeve slot 205', and thus impacts the
resulting fluid flow profile. However, in both FIGS. 13 and 15, the
stem 212' has been moved downwardly sufficiently that there is
little, if any, fluid flow from the housing inlet 204' to the
outlet 206'.
[0076] This results in a lower fluid flow to the inlet of fixed
orifice 50, and thus a lower pressure at P2, and a lower fluid flow
and pressure in the first low pressure regulating chamber 302.
Thus, the pressure differential across fixed orifice 50 lessens,
such that pressures at P2 and P3 are more balanced with one
another. This results in a balancing of pressures between low
pressure regulating chambers 302 and 304. Thus, the bias of spring
320 serves to push diaphragm 306 upwardly, as shown in FIG. 9.
Movement of the diaphragm 306 causes the stem 324 to move upwardly
as well and into contact with the control poppet 338, moving the
control poppet 338 upwardly so as to constrict the fluid flow
through chamber 340.
[0077] This causes a back pressure, which increases in control
chamber 120 of the main valve assembly 100, preventing the main
valve member 110 from moving upwardly, or if sufficient pressure is
present in control chamber 120, moving the main valve member 110
downwardly toward seat 108 to restrict the flow of fluid through
the main valve 100.
[0078] The passage area through the variable orifice 214 changes
with the change in the main valve member 110 position. Main valve
number 110 position changes in response to system flow demand
conditions, opening as demand increases and closing as demand
decreases. Restricted flow through the variable orifice 214 causes
a low pressure drop, or pressure differential, through the fixed
orifice 50, which causes restricted flow through the control pilot
valve apparatus 300. This action causes the main valve 100 to
throttle closed towards a lower pressure set point. The lower
pressure set point is established by adjusting set screw 312, which
compresses or relaxes spring 320, directly affecting the range of
travel and motion of lower diaphragm 306.
[0079] However, when system flow demand increases, the main valve
100 responds by opening, which increases flow area through the
variable orifice 214, as described above. Increased flow through
the variable orifice 214 increases the pressure drop, or
differential, across fixed orifice 50. This action causes the main
valve 100 to throttle open towards the higher set point, as
described above.
[0080] Due to the varying flow of fluid through the variable
orifice 214, the pressure acting on the lower diaphragm 306 also
varies. As pressure above the diaphragm 306 in chamber 302
increases, it forces the diaphragm 306 downwardly, disengaging the
stem 324 from the poppet 338, and allowing fluid to flow freely
through the high pressure regulating chamber 340. This relatively
free flow of fluid reduces the fluid pressure in chamber 120 of the
main valve, permitting the main valve member 110 to remain open.
However, when the pressure on the top of the diaphragm 306, in
chamber 302, is equal to or slightly higher than the pressure under
the diaphragm 306, in chamber 304, then hydraulic and spring forces
bias the travel of the stem 324 upwardly so as to engage and move
the control poppet 338 into a constricted or increasingly closed
position. The fluid flow passageway between the inlet 342 and
outlet 344 of the high pressure regulating chamber 340 varies with
changing system conditions, causing flow to modulate. This action,
as described above, causes the main valve 100 to throttle towards
the low pressure, or low flow, set point. This arrangement allows
the main valve 100 to modulate between the pre-selected high and
low pressure set points established at the control pilot valve
apparatus 300, as described above.
[0081] Although several embodiments have been described for
purposes of illustration, various modifications may be made without
departing from the scope and spirit of the invention. Accordingly,
the invention is not to be limited, except as by the appended
claims.
* * * * *