Abstract:
A constant-flow control valve and BTU meter assembly that has a pressure independent, constant-flow control valve assembly connectable to the fluid-based heating or cooling system. A valve stem is connected to a valve member and is rotatable as a unit relative to a valve body to change the position of valve member to change a fluid flow rate through the valve. The valve member&#39;s position relative to the fluid path is directly related to the fluid flow rate. A BTU meter assembly is connected to the valve stem, which is rotatable relative to the BTU meter assembly. A position sensor of the BTU meter assembly detects a rotational position of the valve stem relative to the BTU body. A controller of the BTU meter assembly determines the fluid flow rate based upon the pressure drop across the valve assembly and the rotational position of the valve stem.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a non-provisional patent application that hereby claims priority to U.S. Provisional Patent Application No. 61/433,632, titled “Pressure Compensated Flow-Rate Controller With BTU Meter,” filed Jan. 18, 2011, and which is incorporated herein in its entirety by reference thereto. 
    
    
     TECHNICAL FIELD 
     Embodiments of the present invention are directed to flow rate controllers and BTU meters. 
     BACKGROUND 
     Flow control valves are used extensively to control fluid flow in heating and cooling systems used to control thermal loads in, as an example, buildings or other spaces. Conventional heating and chilled water systems system utilized the flow control valves control the flow of fluid through the system as needed to meet the heating or cooling needs, such as may be indicated by a thermostat or other control system. The systems also typically monitor the amount of energy being used in the heating and chilled water system via BTU (British Thermal Units) meters. 
     BTU meters are used in buildings to measure heat consumed in building HVAC systems for both performance monitoring and billing purposes. BTU meters for building applications are most commonly comprised of a computer connected to a liquid flow meter and temperature sensors before and after a heating or cooling load. The flow rate measured multiplied by the temperature difference across the heating or cooling coil multiplied by a constant is equal to the BTUs transferred to (cooling) or from (heating) the load. 
     U.S. Pat. No. 5,904,292 discloses an electrically driven valve connected to a cooling or heating load, such as a coil, with temperature sensors before and after the coil with the system controlled and monitored by a computer. This valve is not a pressure balanced device so a change in pressure drop across the valve section would result in change in flow rate measured in the built in flow meter. The motor would then need to adjust the stem. While making this adjustment valves in parallel with the valve undergoing adjustment would then be effected with respect to pressure drop. The result of the interdependence on all valves is that the flow rates will cycle in rate never reaching a constant flow through the heating or cooling coil. 
     SUMMARY 
     Aspects of the present invention are directed to flow rate controller and BTU meter assemblies, systems and methods that overcome drawbacks experienced in the prior art and provide additional benefits. In accordance with aspects of an embodiment include an energy consumption monitoring system for a fluid-based heating or cooling system with a fluid flow therethrough. The system comprises a heating or cooling device, a supply line connected to the heating or cooling device, and a return line connected to the heating or cooling device. The supply line carries fluid to the heating or cooling device at a first temperature, and the return line carries fluid from the heating or cooling device at a second temperature different than the first temperature. A first temperature sensor is coupled to the supply line and is positioned to measure the first temperature, and a second temperature sensor is coupled to the return line and is positioned to measure the second temperature, wherein the temperature difference between the first and second temperatures is a temperature change across the heating or cooling device. 
     The system includes a pressure independent, constant-flow control valve assembly that has a valve body with an inlet and an outlet, a valve chamber therein, and a fluid path extending between the inlet, outlet and the valve chamber. An adjustable valve member is in the valve chamber and disposed in the fluid path. A valve stem is connected to the valve member. The valve stem is rotatable relative to the valve body to adjust the valve member and to adjust a fluid flow rate through the fluid path. The position of the valve member relative to the fluid path is directly related to the fluid flow rate through the fluid path. A first fluid pressure sensor is positioned to measure the fluid pressure of fluid entering the inlet of the valve body, and a second fluid pressure sensor is positioned to measure the fluid pressure of fluid exiting the outlet of the valve body. The difference between the first and second pressures is the pressure drop across the valve. 
     A BTU meter assembly is connected to a free end portion of the valve stem projecting from the valve body, wherein the valve stem is rotatable relative to at least a portion of the BTU meter assembly. The BTU meter assembly comprises a BTU body and a position sensor, which is coupled to the BTU body and to the valve stem. The position sensor is configured to detect the rotational position of the valve stem relative to the BTU body. The BTU meter assembly has a controller coupled to the position sensor, to the first and second pressure sensors, and to the first and second temperature sensors. The controller is configured to determine the fluid flow rate based upon the pressure drop across the valve and the rotational position of the valve stem. The controller is configured to determine energy usage of the heating or cooling device in real time based upon the flow rate and the temperature change across the heating/cooling device. 
     Aspects of one or more embodiments may include the following: the BTU meter can include a BTU body and a rotatable fitting connected to the BTU body, wherein the rotatable fitting is fixedly attached to the free end portion of the valve stem and is rotatable with the valve stem as a unit relative to the BTU and valve bodies. The position sensor is calibrated to detect the rotational position of the valve stem relative to a predetermined reference point directly related to a reference position of the adjustable valve member in the valve chamber. The BTU meter assembly is carried by the pressure independent, constant-flow control valve assembly. The heating or cooling device is a component of a heating and chilled water system. The heating or cooling device can be a heat exchanger, a boiler, a condenser, or a chiller. The valve stem is automatically adjustable in response to instructions from the controller. The valve stem, the valve member, and the rotatable fitting can be interconnected and rotatable together as a unit relative to the BTU body. The controller can be exterior of the BTU body. 
     Another aspect of the embodiments provides a constant-flow control valve and BTU meter assembly that comprises a pressure independent, constant-flow control valve assembly connectable to the fluid-based heating or cooling system. The assembly has a valve body with an inlet and an outlet, a valve chamber with a fluid path therein extending between the inlet and outlet, and an adjustable valve member in the valve chamber and disposed in at least a portion of the fluid path to define a throttle in the fluid path. A valve stem is connected to the valve member and is rotatable as a unit relative to the valve body to change the position of valve member to change a fluid flow rate through the valve body. The position of the valve member relative to the fluid path is directly related to the fluid flow rate through the fluid path. A first fluid pressure sensor is positioned to measure the fluid pressure of fluid entering the inlet of the valve body, and a second fluid pressure sensor is positioned to measure the fluid pressure of fluid exiting the outlet of the valve body. The difference between the first and second pressures is the pressure drop across the valve assembly. 
     A BTU meter assembly is connected to the free end portion of the valve stem, wherein the valve stem is rotatable relative to at least a portion of the BTU meter assembly. The BTU meter assembly has a BTU body and a position sensor coupled to the BTU body and to the valve stem. The position sensor is configured to detect a rotational position of the valve stem relative to the BTU body. The BTU meter assembly has a controller coupleable to the position sensor, to the first and second pressure sensors, and to the first and second temperature sensors. The controller being is to determine the fluid flow rate based upon the pressure drop across the valve assembly and the rotational position of the valve stem. The controller is configured to determine energy usage of the heating or cooling device based upon the flow rate and the temperature change across the heating or cooling device. 
     Another aspect of the embodiments includes a method of determining energy consumption of a fluid-based heating or cooling system with a heating or cooling device and fluid flowing therethrough. The method comprises determining a first temperature of fluid flowing in a supply line to the heating or cooling device, and determining a second temperature of fluid flowing in a return line from the heating or cooling device. Further, determining a first fluid pressure of fluid entering an inlet of a pressure independent, constant-flow control valve assembly that controls a flow rate of the fluid in the fluid-based heating or cooling system. Further, determining a position of the valve stem relative to the valve body or the BTU body, and determining a second fluid pressure of fluid exiting the outlet of the control valve assembly, wherein a difference between the first and second fluid pressures corresponds to a pressure drop across the valve. Further, determining the flow rate of fluid passing through the control valve assembly based on the pressure drop across the valve and the position of the valve stem relative to the valve body or the BTU body, and determining energy consumption of the heating or cooling device in real time based upon the determined flow rate and the temperature change across the heating or cooling device. 
     Aspects of the method can include determining the first temperature includes sensing the first temperature with a first temperature sensor coupled to the controller and coupled to the supply line, and determining the second temperature includes sensing the second temperature with a second temperature sensor coupled to the controller and coupled to the return line. The method can include determining the flow rate includes detecting a rotational position of the valve stem relative to a predetermined reference point associated with at least one of the valve body or the BTU body. The method can include determining energy consumption of the heating or cooling device includes determining the energy consumption of at least one of a heat exchanger, a boiler, a condenser, or a chiller. The method can also include determining the position of the valve stem comprises determining with a position sensor a rotational position of the valve stem relative to the valve body or BTU body. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is a schematic cross-sectional view of a pressure independent valve connected to a BTU meter in accordance with an aspect of the disclosure. 
         FIG. 1B  is an enlarged cross-sectional view of a portion of the pressure independent valve of  FIG. 1A . 
         FIG. 2  is an isometric view of a flow control valve assembly with an integral BTU meter in accordance with an embodiment of the present invention. 
         FIG. 3  is another isometric view of the flow control valve assembly with an integral BTU meter of  FIG. 1 . 
         FIG. 4  is another isometric view of the flow control valve assembly with an integral BTU meter of  FIG. 1 . 
         FIG. 5  is a bottom isometric view of the flow control valve assembly with an integral BTU meter of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
     The present invention provides a flow control valve assembly with a flow control valve an integral BTU meter that overcomes drawbacks experienced in the prior art. The present disclosure describes a flow control valve assembly in accordance with certain embodiments of the present invention. Several specific details of the invention are set forth in the following description and the Figures to provide a thorough understanding of certain embodiments of the invention. One skilled in the art, however, will understand that the present invention may have additional embodiments, and that other embodiments of the invention may be practiced without several of the specific features described below. 
       FIG. 1  is a schematic, cross-sectional view of a flow control assembly  10  with a pressure compensated flow rate controller  12  and an integral BTU meter  14  in accordance with embodiments of the present invention. In the illustrated embodiment, the pressure compensated flow rate controller  12  is operatively connected to a computer  13  configured to monitor temperature sensors  15  before and after a heating or cooling load in a heating and chilled water system  11 . The computer  13  can also monitor pressure sensors P 1 , P 2  and P 3  in addition to valve stem position (discussed in greater detail below) and an optional air temperature sensor. The position of an internal rate control piston  26  can also be monitored by a proximity sensor  17  that, in turn, is monitored by the computer  13 . 
     The pressure compensated flow rate controller  12  in at least one embodiment includes a pressure independent flow control valve  19  that provides constant flow rate at the same stem set point with large fluctuations in pressure drop across the valve. Provided a minimum pressure drop is applied to the valve  19 , the flow rate through the valve is very predictable for each stem set point. This rate control technology and a pressure independent flow rate controller are described in detail in U.S. Pat. No. 7,128,086, titled Flow Control Valves, issued Oct. 31, 2006, and which is incorporated herein in its entirety by reference thereto. This constant flow produces a system where valves and motor driven stems do not cyclically hunt in attempt to produce constant flow. 
     The computer  13  monitors the stem position and in combination with the P 1  and P 3  pressure sensors  21  to check for minimum pressure drop to infer the flow rate. This flow rate is then multiplied by the difference in temperature across the heating or cooling load (e.g. a coil) to determine the BTU rate being transferred. An alternate to measuring the P 1  and P 3  sensors  21  is to monitor the position sensor  17  and/or that the rate control piston  26  has moved into its throttling position which would be caused by a minimum pressure drop applied across the valve. 
     The stem inference and constant flow without cyclic hunting allows the stem position to substitute the flow meter listed in the  292  patent. Eliminating this flow meter eliminates a multitude of maintenance and calibration issues (such as fowling turbines in flow meters, regular calibration cycles for any flow meter) over the life of the building and produces a flow inference system that has a large range (turn down) and flow rate accuracy over the range that is associated with industrial flow meters that would be cost prohibitive for HVAC systems. Note: BTU meters in buildings use low cost turbine or impeller wheel meters that fowl so BTU meter in buildings are not that popular. 
     Constant flow through the cooling or heating load without cyclic rate allows for more accurate BTU rate monitoring than if a cyclic flow rate is applied because temperature sensors will experience delay in reading. This thermal delay is typically caused by a change in flow which typically causes a change in temperature through the coil. 
       FIGS. 1-5  show an embodiment of the assembly  10  in accordance with at least one embodiment of the invention. The illustrated assembly  10  has the flow control valve  19  integrally connected to the BTU meter  14 . The flow control valve  19  is a high-performance pressure-independent constant flow configured to maintain a constant flow rate across the valve independent of any fluid pressure differentials or fluctuations between the inlet  16  and the outlet  18  of the valve. In one embodiment, the pressure independent flow control valve  19  is a DeltaP Valve®, manufactured and sold by Flow Control Industries, Inc., of Woodinville, Wash. Other embodiments can use other pressure independent flow control valves that provide sufficient accuracy and performance. 
     The valve  19  includes a housing  20  that defines the inlet  16  and the outlet  18  and that contains the internal components  22  of the valve, such as an internal passageway  24  connected to the inlet  16  and outlet  18 , a spring biased piston  26  movably disposed adjacent to a piston seat  28  through which the water or other fluid can flow as the water moves through the flow passageway  24 . The valve  19  includes a flow throttle  30  rotatably disposed in a cavity within the flow passageway  24 . The flow throttle  30  has an opening  32  configured to selectively permit fluid to flow from the inlet  16 , past the piston  26  and piston seat  28  (when the valve is not closed), to the outlet. The flow throttle  30  is connected to a valve stem  34  that is rotatably adjustable so as to rotate the flow throttle  30  within the flow passageway  24 . Accordingly, the flow rate through the valve  19  can be very accurately adjusted by rotating the valve stem  34 , thereby rotating and adjusting the flow throttle  30 . 
     The valve  19  of the illustrated embodiment is a high performance valve with high “turn down”, which equals the valve&#39;s highest flow rate divided by the lowest flow rate achievable. For a fixed valve orifice, the turn down is calculated by taking the square root of the highest pressure drop across the orifice divided by the lowest pressure drop. For example, a valve that offers a pressure drop across the orifice of 200 psi at maximum flow and 2 psi at minimum flow will have a turn down of 10:1. The valve  19  of the illustrated embodiment has a turn down of approximately 100:1, and the valve will operate in the pressure independent range from approximately 5-70 PSID (0.34-4.83 bar), inclusive. In other embodiments, the valve  19  can have a higher operating range of approximately 10-90 PSID (0.7-6.2 bar), inclusive. Other embodiments can include other high performance valves that have different turn downs and/or different operating ranges. 
     The valve  19  of the illustrated embodiment that provides a constant flow rate through the valve independent of pressure drops across the valve and that has the turn down of approximately 100:1, allows the user to very accurately control the fluid flow through the entire pressure independent range, by adjusting the stem  34  and the flow throttle  32 . 
     As seen in  FIGS. 1-5 , a support plate  40  has an attachment portion  42  securely attached to the valve  19 , and a platform portion  44  attached to the arm portion  32 . The BTU meter  14  mounted on the platform portion  44 , so that the BTU meter is securely supported in a fix position adjacent to the valve  19 . As seen in  FIGS. 2 and 5 , the platform portion  44  has an aperture  46  therein coaxially aligned with the stem  34  of the valve  19 . The stem  34  extends away from the valve&#39;s housing, and a distal end portion  40  of the stem  34  extends through the platform portion&#39;s aperture  46  and into a rotatable fitting  48  in the BTU meter. The stem  34  is fixedly attached to the rotatable fitting  48  so that when the stem is rotated (manually or automatically in response to instructions from a controller), the stem  34 , the throttle  32 , and the fitting  48  all rotate together as a unit relative to the BTU meter  14 . 
     The BTU meter  14  has a position sensor  50  connected to the fitting  48  and calibrated to accurately and precisely detect the angular position of the fitting  48  and the stem  34  of the valve. The position sensor  50  is coupled to a controller  52  that received data about the rotational position of the fitting  48  and/or the stem  34 . As indicated above, the valve  19  is a high performance pressure independent valve with a high turn down, which provides for very accurate control of the water flow rate through the valve. Once the stem  34  and throttle  30  have been rotated to a selected position the flow rate through the valve remains constant independent of pressure fluctuations. This highly accurate control of the fluid flow rate is such that the valve  19  can be calibrated to very accurately identify or determine the fluid flow rate through the valve based on the position of the stem  34  (e.g., the angular position of the stem), and thus the throttle  30 . The position sensor  50  is also calibrated to accurately detect the position of the stem relative to a predetermined referenced point. Accordingly, the controller  52  uses the data from the position sensor about the position of the stem  34  to very accurately determine the actual flow rate of water through the valve  19 . 
     In the illustrated embodiment, the controller  52  of the BTU meter  14  is coupled to temperature sensors  15  positioned at selected locations in a heating and cooling system  11 , shown schematically. The controller  52  receives data from the temperature sensors  15 , such as one temperature sensor for supply water and another for the return water of a heat exchanger. The controller  52  is configured to calculate the energy consumption based on the flow rate data and the temperature sensor data. The result is a very accurate measurement of energy consumption in real time by the BTU meter  14  because the calculation utilizes the actual flow rate information from the pressure independent constant flow rate to which the rotational position of the stem is accurately correlated and calibrated. 
     In at least one embodiment, the assembly includes an air temperature sensor  58  and air flow sensor  60  shown in  FIG. 1 . The air temperature sensor  58  and air flow sensor  60  can also be monitored by the computer  13  discussed above. In conjunction with fan on/off indication this sensor can be used to monitor cooling or heating coil performance. The air temperature sensors can also be used to control the stem position and to vary the flow fluid through the cooling or heating coil to maintain a desired air temperature. 
     From the foregoing, it will be appreciated that specific embodiments of the invention have been described herein for purposes of illustration, but that various modifications may be made without deviating from the invention. Additionally, aspects of the invention described in the context of particular embodiments or examples may be combined or eliminated in other embodiments. Although advantages associated with certain embodiments of the invention have been described in the context of those embodiments, other embodiments may also exhibit such advantages. Additionally, not all embodiments need necessarily exhibit such advantages to fall within the scope of the invention. Accordingly, the invention is not limited except as by the appended claims.