Patent Publication Number: US-10760712-B2

Title: Fluid regulators

Description:
RELATED APPLICATIONS 
     This disclosure arises from a division of U.S. patent application Ser. No. 14/675,448, filed Mar. 31, 2015, entitled “Fluid Regulators,” the entirety of which is hereby incorporated herein by reference. 
    
    
     FIELD OF THE DISCLOSURE 
     This disclosure relates generally to fluid control devices and, more particularly, to fluid regulators. 
     BACKGROUND 
     Fluid regulators may receive a relatively high pressure at an inlet and provide a relatively lower set control pressure at an outlet. In some instances, the flow through the outlet may vary based on the downstream demand of the system to which the fluid regulator is coupled. 
     SUMMARY 
     Fluid regulators are disclosed. In some disclosed examples, an apparatus comprises a vale body, a valve seat, and protrusions. In some disclosed examples, the valve body has an inlet and an outlet. In some disclosed examples, the valve seat is located within the valve body and is positioned between the inlet and the outlet. In some disclosed examples, the protrusions are formed by and extend along an inner wall of the valve body between the valve seat and the outlet, and end adjacent the outlet. In some disclosed examples, at least one of the protrusions is spaced relative to others of the protrusions. In some disclosed examples, the protrusions are to increase a uniformity of a flow pattern of fluid flowing through a cross-section of the outlet. In some disclosed examples, each of the protrusions has a central axis oriented perpendicularly to a corresponding surrounding portion of the inner wall. 
     In some disclosed examples, an apparatus comprises a valve body, a valve seat, protrusions, and a pitot tube. In some disclosed examples, the valve body has an inlet and an outlet. In some disclosed examples, the valve seat is located within the valve body and is positioned between the inlet and the outlet. In some disclosed examples, the protrusions are formed by and extend along an inner wall of the valve body between the valve seat and the outlet, and end adjacent the outlet. In some disclosed examples, at least one of the protrusions is spaced relative to others of the protrusions. In some disclosed examples, the pitot tube has a sensing end located downstream from the valve seat and upstream from the protrusions. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows an example fluid regulator in accordance with the teachings of this disclosure. 
         FIG. 2  shows a portion of the example fluid regulator of  FIG. 1  including an example first aperture pattern defined within an example outlet flow path. 
         FIG. 3  shows the portion of the example fluid regulator of  FIG. 1  including an example second aperture pattern defined within the example outlet flow path. 
         FIG. 4  shows the portion of the example fluid regulator of  FIG. 1  including an example first protrusion pattern defined within the example outlet flow path. 
         FIG. 5  shows the portion of the example fluid regulator of  FIG. 1  including an example second protrusion pattern defined within the example outlet flow path. 
         FIGS. 6-9  show example test results obtained using the examples disclosed herein. 
         FIG. 10  shows another example fluid regulator in accordance with the teachings of this disclosure. 
         FIG. 11  shows another example fluid regulator in accordance with the teachings of this disclosure. 
         FIG. 12  shows another example fluid regulator in accordance with the teachings of this disclosure. 
     
    
    
     The figures are not to scale. Wherever possible, the same reference numbers will be used throughout the drawing(s) and accompanying written description to refer to the same or like parts. 
     DETAILED DESCRIPTION 
     Some known fluid regulators exhibit unpredictable flow and/or pressure at their outlets. If the flow pattern of a fluid exiting the outlet of a regulator is relatively unpredictable, a sensor (e.g., a pitot tube) positioned downstream of the regulator may be unable to provide accurate and/or reliable readings. Such inaccurate readings may result in the regulator under traveling and/or over traveling and, more generally, for the set downstream pressure to not be consistently maintained. 
     In contrast to some of these known regulators, using the examples disclosed herein, outlet flow is caused to be more predictable and/or repeatable enabling downstream sensors to provide more accurate readings and increase the usable capacity of the regulator. For example, to increase the predictability of the outlet flow, reduce boost and/or increase delivery pressure, the outlet paths of the example fluid regulators disclosed herein include surface structures that cause stratification of the fluid flow. In some examples, stratification of the fluid flow enables the flow pattern through the outlet path to be predictable and/or repeatable over various pressure drops (e.g., a 10 pounds per square inch (PSI) pressure drop, a 90 PSI pressure drop, etc.). 
     In some examples, the example surface structures within the outlet flow paths increase the pressure of the fluid flow in the middle of the outlet path by reducing fluid velocity and decrease the pressure of the fluid flow immediately adjacent the walls of the outlet path by increasing fluid velocity. Thus, by increasing the fluid velocity immediately adjacent the walls of the outlet path and decreasing the fluid velocity in the middle of the outlet path, the example surface structures enable fluid pressure and/or velocity across a cross-section of the outlet to be relatively consistent and/or uniform. In some examples, the surface structures within the outlet path include concave dimples, convex dimples, apertures, protrusions and/or texturing such as sharkskin texturing. The surface structures may be disposed in an irregular pattern, a random pattern and/or a consistent or regular pattern. 
       FIG. 1  shows an example regulator  100  that includes an actuator  102  coupled to a regulator valve  104 . The actuator  102  includes a diaphragm  106  that is captured within an actuator housing  108  to define a loading chamber  110  and a sensing chamber  112 . To provide a control load and/or pressure to a first side  114  of the diaphragm  106 , the loading chamber  110  receives a control fluid, via an inlet port  116 , and houses a spring  118  that acts against the diaphragm  106 . In some examples, the control load and/or pressure provided by the spring  118  and/or the control fluid corresponds to a desired outlet pressure provided by the regulator  100 . 
     The regulator valve  104  of  FIG. 1  includes a valve body  120  defining a fluid passageway  122  between an inlet  124  and an outlet  126 . In this example, the valve body  120  is coupled to the actuator housing  108  such that a throat  128  of the valve body  120  is in fluid communication with the sensing chamber  112  to enable the sensing chamber  112  and/or a pitot tube  130  disposed within the throat  128  to sense the pressure at the outlet  126  of the valve body  120 . To control fluid flow through the valve body  120 , a plug  131  is disposed within the passageway  122  to move relative to a valve seat and/or orifice  132 . In this example, the plug  131  is coupled to the diaphragm  106  via linkage  134 . However, the plug  131  may be coupled to the diaphragm  106  in any suitable way. 
     In operation, in the example of  FIG. 1 , the diaphragm  106  moves the valve plug  131 , via the linkage  134 , in response to a pressure differential across the diaphragm  106 . When the downstream demand increases and causes the downstream pressure to decrease below the control load and/or pressure, a pressure differential across the diaphragm  106  and the spring  118  force causes the diaphragm  106  to move toward the sensing chamber  112 , thereby moving the valve plug  131  away from the valve seat  132  to enable fluid flow through the passageway  122 . When the downstream demand decreases and causes the downstream pressure to increase above the control load and/or pressure, the pressure differential across the diaphragm  106  causes the diaphragm  106  to move toward the loading chamber  110 , thereby moving the valve plug  131  toward the valve seat  132  to prevent or reduce fluid flow through the passageway  122 . 
     The regulator  100  may be categorized by a certain capacity rating or accuracy classification based on the ability of the regulator  100  to maintain an outlet pressure at the set control pressure when the regulator  100  is exposed to a range of pressure differentials and, thus, fluid flow rates. When the regulator  100  provides a downstream outlet pressure that deviates from the set control pressure, the regulator  100  is no longer controlling within that particular operating parameter and its accuracy classification or capacity is significantly degraded. 
     For example, when the regulator  100  is exposed to high inlet pressures or high pressure differentials, the regulator  100  may create boost when the downstream pressure suddenly increases and the fluid flows through the passageway  122  at a relatively high velocity. Fluid flow having a relatively high velocity may result in unpredictable pressure areas and/or zones within the throat  128  and/or the outlet  126  to deviate from the downstream pressure. Depending on the pressure drop across the diaphragm  106 , the location of these pressure areas and/or zones may shift, thereby making the ability to accurately sense the pressure using the pitot tube  130  difficult. 
     For example, in some known regulators (i.e., not the regulator  100  of  FIG. 1 ) when a first pressure drop is present across the orifice  132 , vertical pressure gradients that run transverse to a longitudinal axis of the outlet  126  define a first pressure zone may form in a first location within the outlet  126  and, when a second pressure drop is present across the diaphragm  106 , vertical pressure gradients that differently define the first pressure zone may form in a second location within the outlet  126 . As a result of the movement of these pressure areas and/or zones and/or the movement of the vertical pressure gradients, in some examples, placing the pitot tube  130  in a position that obtains reliable pressure readings when the regulator  100  is exposed to different pressure drops is difficult. If the measured pressure is inaccurate (e.g., a lower pressure than the actual outlet pressure), the regulator  100  may deviate from the control pressure, thereby causing the regulator  100  to have a lower capacity rating due to, for example, poor accuracy of the pressure measurements. 
     In contrast to the issues encountered with some known regulators (i.e., not the regulator  100  of  FIG. 1 ), to decrease the boost within the outlet  126 , the examples disclosed herein include surface structures and/or texturing  136  within the outlet  126  that cause the fluid flow within the outlet  126  to have a more consistent and/or uniform velocity, to have more consistent and/or uniform pressure gradients and/or to have a more consistent and/or uniform pressure across a cross-section of the outlet  126 . The surface structures  136  may include apertures, concave dimples, convex dimples, sharkskin surface structures, texturing, etc. However, the surface structures  136  may be any suitable structure, texture and/or pattern that reliably controls the flow of fluid (e.g., gas, liquid, slurry) flowing through the regulator  100 . 
     In some examples, the surface structures  136  are configured to increase turbulence and velocity of the fluid flow immediately adjacent the walls of the outlet  126  and to decrease the turbulence and velocity of the fluid flow in the middle of outlet  126  such that the velocity and/or pressure of the fluid flow across an entire cross-section of the outlet  126  is relatively consistent or uniform. Additionally or alternatively, in some examples, the surface structures  136  are configured to increase a number of horizontal pressure gradients that run along a longitudinal axis of the outlet  126  and to decrease a number of vertical pressure gradients that run transverse to the longitudinal axis of the outlet  126 . In contrast to the vertical pressure gradients present in examples that do not include the surface structures  136  disclosed herein, horizontal pressure gradients that run along a longitudinal axis of the outlet  126  have a tendency to remain in a relatively consistent position even when the regulator  100  experiences different pressure drops across the diaphragm  106 . Thus, using the examples disclosed herein, the pitot tube  130  may be reliably positioned within a pressure area and/or zone (e.g., within a horizontal pressure zone) regardless of the pressure drop across the orifice  132 . Reliable placement of the pitot tube  130  enables relatively more accurate pressure measurements to be obtained, which enables the example regulator  100  to have a higher capacity rating due to, for example, improved accuracy of the pressure measurements. 
       FIG. 2  shows a partial view of the example regulator  100  of  FIG. 1  including example apertures  202  (e.g., shallow recesses) that can be used to implement the example surface structures  136  of  FIG. 1 . In some examples, the apertures  202  are randomly dispersed within the outlet  126 . In some examples, the apertures  202  increase a flow capacity through the outlet  126  by, for example, causing the velocity across a cross-section of the outlet  126  to be relatively consistent. In some examples, the apertures  202  cause a pressure and/or a pressure field across a cross-section of the outlet  126  to be relatively consistent. 
       FIG. 3  shows a partial view of the example regulator  100  of  FIG. 1  including example apertures  302  (e.g., recesses) that can be used to implement the example surface structures  136  of  FIG. 1 . In contrast to the example apertures  202  of  FIG. 2 , more of the apertures  302  of the example of  FIG. 3  are disposed and/or defined by the outlet  126 . In other words, the apertures  302  of  FIG. 3  more densely populate the outlet  126  as compared to the apertures  202  of  FIG. 2 . In some examples, the apertures  302  are randomly dispersed within the outlet  126 . In some examples, the apertures  302  increase a flow capacity through the outlet  126  by, for example, causing the velocity across a cross-section of the outlet  126  to be relatively consistent. In some examples, the apertures  302  cause a pressure and/or a pressure field across a cross-section of the outlet  126  to be relatively consistent. 
       FIG. 4  shows a partial view of the example regulator  100  of  FIG. 1  including example protrusions  402  (e.g., dimples, bumps, etc.) that can be used to implement the example surface structures  136  of  FIG. 1 . In some examples, the protrusions  402  are randomly dispersed within the outlet  126 . In some examples, the protrusions  402  change (e.g., decrease) a flow capacity through the outlet  126  by, for example, causing the velocity across a cross-section of the outlet  126  to be relatively consistent. 
       FIG. 5  shows a partial view of the example regulator  100  of  FIG. 1  including example protrusions  502  (e.g., dimples, bumps, etc.) that can be used to implement the example surface structures  136  of  FIG. 1 . In contrast to the example protrusions  402  of  FIG. 4 , more of the protrusions  502  of the example of  FIG. 5  are disposed and/or defined by the outlet  126 . In other words, the protrusions  502  of  FIG. 5  more densely populate the outlet  126  as compared to the protrusions  402  of  FIG. 4 . In some examples, the protrusions  502  are randomly dispersed within the outlet  126 . In some examples, the protrusions  502  may be advantageously used in connection with lower pressure drops across the orifice  131 . 
       FIGS. 6-8  are pressure contour representations of regulators including example surface structures disclosed herein and regulators having an outlet with a smooth surface (e.g., no surface structures). 
       FIG. 6  shows results of a 10 PSI pressure drop across a regulator not including surface structures at the outlet  126  and  FIG. 7  shows results of the 10 PSI pressure drop across a regulator including surface structures as disclosed herein. As shown when comparing  FIGS. 6 and 7 , a pressure zone  602  of  FIG. 6  is relatively smaller and closer to the valve seat  132  as compared to a pressure zone  702  of  FIG. 7  that is relatively larger and farther away from the valve seat  132 . As used herein, the phrase “pressure zone” means an area within the outlet  126  in which the pressure is relatively consistent and/or at an expected pressure. 
       FIG. 8  shows results of a 90 PSI pressure drop across a regulator not including surface structures at the outlet  126  and  FIG. 9  shows results of the 90 PSI pressure drop across a regulator including surface structures as disclosed herein. In  FIG. 8 , vertical pressure gradients  802 ,  804 ,  806  are present that run transverse to a longitudinal axis of the outlet  126  and define pressure zones  808 ,  810 ,  812 . The pressure gradients  802 ,  804 ,  806  and, thus, the pressure zones  808 ,  810 ,  812  tend to shift as the pressure drop changes and/or based on other conditions. The movement or shifting of the vertical pressure gradients  802 ,  804 ,  806  over different pressure drops increases the difficultly of positioning the pitot tube  130  to obtain reliable measurements over a range of flow conditions and/or pressure drops across the valve seat  132 . In contrast, in  FIG. 9 , horizontal pressure gradients  902 ,  904  that run along a longitudinal axis of the outlet  126  are present and define pressure zones  906 ,  908 . The horizontal pressure gradients  902 ,  904  and, thus, the pressure zones  906 ,  908  form in locations that are relatively stable as the pressure drop across the orifice  132  changes. Thus, the horizontal pressure gradients  902 ,  904  enable the pitot tube  130  to be positioned in a location that obtains reliable, consistent readings regardless of the pressure drop across the orifice  132 . 
       FIG. 10  shows another example regulator  1000  similar to the example regulator  100  of  FIG. 1 . However, in contrast to the example regulator  100  of  FIG. 1 , the example regulator  1000  of  FIG. 10  includes example tubes  1002  disposed within the outlet  126  instead of the example surface structures  136 . In some examples, the tubes  1002  can be implemented using a laminar flow element and may be relatively parallel to one another (e.g., between about 5 degrees of parallel). Further, the pitot tube  130  of the example regulator  1000  of  FIG. 10  is disposed in a different location downstream of the tubes  1002 . 
     In the example of  FIG. 10 , the tubes  1002  are coupled together with fastener(s)  1004 . The fastener(s)  1004  may be straps and/or ties, etc. In this example, the outlet  126  includes a ledge  1006  against which the tubes  1002  engage and/or are coupled using one or more fasteners (e.g., bolts). In other examples, the tubes  1002  are coupled within the outlet  126  using a retaining ring(s), another faster, etc. 
     In operation, when fluid flows through the tubes  1002 , the tubes  1002  cause the flow of fluid across a cross-section of the outlet  126  to be relatively consistent or uniform by causing the fluid to flow in substantially parallel paths through the tubes  1002 , thereby substantially reducing and/or eliminating turbulence in the flow. Thus, as with the surface structures  136  disclosed in connection with  FIG. 1 , the tubes  1002  enable pressure zones within the outlet  126  to remain relatively stable and/or consistent and/or improve the consistency of the downstream pressure being measured by making the fluid flow across a cross-section of the outlet  126  relatively consistent. 
       FIG. 11  shows another example regulator  1100  similar to the example regulator  1000  of  FIG. 10 . However, in contrast to the example regulator  1000  of  FIG. 10 , the example regulator  1100  of  FIG. 11  includes a porous body  1102  disposed within the outlet  126  instead of the example tubes  1002 . In some examples, the porous body  1102  is implemented using metal lattice. In this example, the outlet  126  includes the ledge  1006  against which the porous body  1102  engages and/or is coupled using one or more fasteners (e.g., bolts). In other examples, the porous body  1102  is coupled within the outlet  126  using a retaining ring(s), another fastener, etc. 
     In operation, when fluid flows through the porous body  1102 , the porous body  1102  causes the flow of fluid across a cross-section of the outlet  126  to be relatively consistent by breaking up turbulence in the flow. For example, when the fluid flows though the porous body  1102 , a pressure of the fluid flow in the middle of the outlet path increases by reducing velocity of the fluid and the pressure of the fluid flow immediately adjacent the walls of the outlet path decreases by increasing the velocity of the fluid. Thus, as with the surface structures  136  disclosed in connection with  FIG. 1 , the porous body  1102  enables pressure zones within the outlet  126  to remain relatively stable and/or consistent and/or improves the consistency of the downstream pressure being measured by making the fluid flow across a cross-section of the outlet  126  relatively consistent. 
       FIG. 12  shows another example regulator  1200  similar to the example regulator  1000  of  FIG. 10 . However, in contrast to the example regulator  1000  of  FIG. 10 , the example regulator  1200  of  FIG. 12  includes a plate  1202  including a plurality of apertures  1204  disposed within the outlet  126  instead of the example tubes  1002 . In some examples, the apertures  1204  are substantially parallel relative to one another (e.g., between about 5 degrees of parallel). In this example, the outlet  126  includes the ledge  1006  against which the plate  1202  engages and/or is coupled using one or more fasteners (e.g., bolts). In other examples, the porous body  1102  is coupled within the outlet  126  using a retaining ring(s), another fastener, etc. 
     In operation, when fluid flows through the apertures  1204 , the apertures  1204  cause the fluid flow across a cross-section of the outlet  126  to be relatively consistent by causing the fluid to flow in substantially parallel paths through the apertures  1204 , thereby substantially reducing and/or eliminating turbulence in the flow. Thus, as with the surface structures  136  disclosed in connection with  FIG. 1 , the plate  1202  and the corresponding apertures  1204  enable pressure zones within the outlet  126  to remain relatively stable and/or consistent and/or improve the consistency of the downstream pressure being measured by making the fluid flow across a cross-section of the outlet  126  relatively consistent. 
     From the foregoing, it will be appreciated that the above disclosed methods, apparatus and articles of manufacture relate to fluid control devices such as regulators that include a flow chamber having example surface structures that substantially increase and/or distribute turbulence within an outlet path of the fluid control device. In some examples, the surface structures substantially reduce and/or eliminate laminar flow and/or stagnation within the outlet path of the fluid control device regardless of, for example, the pressure drop across the fluid control device. In some examples, the surface structures substantially improve the consistency of the downstream pressure being measured, decrease boost and/or increase the overall capacity of the example fluid control devices implemented with the example surface structures disclosed herein. 
     In some examples, the example surface structures substantially disrupt, break up, or prevent turbulence within the outlet path to increase fluid flow stability. In some examples, the surface structures include example air injectors, example tube bundles, example plates with holes and/or example porous bodies may be disposed within the outlet path. Thus, in such examples, the example surface structures includes an insert such as a tube bundle, a plate with holes, etc., disposed within and/or removably coupled within the outlet path. In some examples, the surface structures substantially increase usable capacity of the fluid regulator. Some examples disclosed herein increase delivery pressure accuracy to enable more accurate consumption prediction and/or improve the efficiency of downstream components. Some examples disclosed herein enable smaller regulators to be more versatile and used in applications where larger regulators were previously required. While the examples disclosed herein teach surface structures disposed within the outlet path of a valve coupled to a fluid regulator, the example surface structures may be implemented on interior surfaces (e.g., inlet surfaces, outlet surfaces, etc.) of any fluid control device. 
     Using the examples disclosed herein, an example regulator may more reliably predict consumption data of downstream components, improve the efficiency of downstream components and, more generally, improve outlet flow regulation and/or enable more versatility for smaller regulators. Additionally, in some examples, providing the output path with example surface structures that stabilize the outlet flow enables the flow rate and/or flow capacity through the outlet of such regulators to increase. 
     As set forth herein, an example apparatus includes a valve body including an inlet, an outlet, and an aperture disposed between the inlet and the outlet, the outlet includes surface structures to increase a uniformity of a flow pattern of fluid flowing through a cross-section of the outlet. In some examples, the increase in the uniformity enables pressure gradients that are defined along a longitudinal axis of the outlet to be formed within the outlet, the pressure gradients to define a pressure zone. In some examples, a location of the pressure zone is to remain substantially consistent when different pressure drops are provided. In some examples, the apparatus includes a pitot tube having an end disposed within the pressure zone. In some examples, the increase in the uniformity is to reduce boost. In some examples, the surface structures include apertures. In some examples, the surface structures include projections. In some examples, the surface structures include texturing. In some examples, the aperture include a valve seat, and the apparatus also includes a plug to selectively engage the valve seat to control fluid flow between the inlet and the outlet. In some examples, the apparatus includes a regulator coupled to the valve body. In some examples, the surface structures include an insert disposed within the outlet. 
     An example apparatus includes a valve body including an inlet, an outlet, and an aperture disposed between the inlet and the outlet. The apparatus includes means for increasing a uniformity of a flow pattern of fluid flowing through a cross-section of the outlet. In some examples, the means for increasing the uniformity comprise surface structures disposed within the outlet. In some examples, the increase in the uniformity enables pressure gradients that are defined along a longitudinal axis of the outlet to be formed within the outlet, the pressure gradients to define a pressure zone. In some examples, a location of the pressure zone is to remain substantially consistent when different pressure drops are provided. In some examples, the apparatus includes a pitot tube having an end disposed within the pressure zone. In some examples, the surface structures include apertures. In some examples, the surface structures include projections. In some examples, the surface structures include texturing. In some examples, the aperture includes a valve seat, and the apparatus also includes a plug to selectively engage the valve seat to control fluid flow between the inlet and the outlet. In some examples, the apparatus include a regulator coupled to the valve body. 
     Although certain example methods, apparatus and articles of manufacture have been disclosed herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus and articles of manufacture fairly falling within the scope of the claims of this patent.