FLUID FLOW CONTROL DEVICE

Abstract

A device (1) for controlling the flow of fluid through a conduit from an upstream side (3) to a downstream side (5). The device includes a housing (4) with a wall (6) having valve apertures (8) through which the flow of fluid is selectively controlled. A valve member (10) is mounted on one side of the wall of the housing and is arranged to move reciprocally to selectively open and close the valve apertures. A removable insert (12) is mounted on the opposite side of the wall of the housing from the valve member. The removable insert is arranged to cover some of the valve apertures.

Claims

1. A device for controlling the flow of a fluid through a conduit from an upstream side of the device to a downstream side of the device, the device comprising: a housing comprising a wall having defined therein a plurality of valve apertures through which the flow of fluid is selectively controlled; a valve member mounted on a first side of the wall of the housing and arranged to move reciprocally to selectively open and close the plurality of valve apertures, thereby controlling flow of the fluid through the plurality of valve apertures; and a removable insert mounted on a second side of the wall of the housing, wherein the second side of the wall is on an opposite side of the wall from the first side of the wall, and the removable insert is arranged to cover some but not all of the plurality of valve apertures so as to prevent the flow of fluid through the some but not all of the plurality of valve apertures.

2. The device as claimed in claim 1, wherein the wall of the housing comprises a cylinder, and each valve aperture of the plurality of valve apertures is arranged to extend radially through the cylindrical wall of the housing.

3. The device as claimed in claim 2, wherein the valve member comprises a cylinder and the removable insert comprises a cylinder.

4. The device as claimed in claim 1, wherein the wall of the housing comprises a cylinder, and a cylindrical valve member is mounted coaxially on the inside of the wall of the housing and arranged to move reciprocally in a direction in which the housing and valve member are cylindrically extended, and the removable insert comprises a cylinder that is mounted coaxially on the outside of the wall of the housing.

5. The device as claimed in claim 1, wherein the removable insert is elastically deformable such that the removable insert is resiliently mounted on the housing.

6. The device as claimed in claim 5, wherein a structure of the removable insert is elastically deformable and/or a material of the removable insert is elastically deformable.

7. The device as claimed in claim 1, wherein the removable insert comprises one or more mounting lugs for securing the removable insert to the housing.

8. The device as claimed in claim 7, wherein each mounting lug of the one or more mounting lugs is arranged to engage with a corresponding feature on the wall of the housing when the removable insert is mounted on the housing.

9. The device as claimed in claim 7, wherein each mounting lug of the one or more mounting lugs is arranged to engage with a corresponding valve aperture.

10. The device as claimed in claim 7, wherein the one or more mounting lugs are arranged so that when mounted on the housing the removable insert fully covers some of the plurality of valve apertures and leaves a remaining group of one or more apertures of the plurality of valve apertures fully open.

11. The device as claimed in claim 1, wherein at least some valve apertures of the plurality of valve apertures are arranged in a plurality of helixes in the wall of the housing.

12. The device as claimed in claim 1, wherein a design of the removable insert is arranged to match a pattern of the valve apertures.

13. The device as claimed in claim 1, wherein the removable insert is arranged to cover an equal proportion of the valve apertures along the length of the housing.

14. The device as claimed in claim 1, wherein the removable insert comprises one or more apertures that extend along a corresponding length of the plurality of valve apertures, wherein the one or more apertures in the removable insert are arranged to leave open an equal proportion of the valve apertures along the length of the housing.

15. The device as claimed in claim 1, wherein the removable insert is rotationally symmetric.

16. A removable insert for mounting in a fluid flow control device and for controlling the flow of a fluid through a plurality of apertures defined in a cylindrical housing of the device, the removable insert comprising an elastically deformable cylindrical body, the cylindrical body comprising one or more helically extended wall sections and one or more helically extended apertures extending around at least part of the circumference of the cylindrical body, wherein the one or more helically extended wall sections are arranged, when the removable insert is mounted on the cylindrical housing of the device, to cover some but not all of the plurality of valve apertures so to prevent the flow of fluid through the some but not all of the plurality of valve apertures and the one or more helically extended apertures are arranged, when the removable insert is mounted on the cylindrical housing of the device, to align with a remaining group of one or more valve apertures of the plurality of valve apertures so allow the flow of fluid through the remaining group of one or more valve apertures.

Description

[0043] Certain preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

[0044] FIG. 1 shows a cutaway view of a fluid flow control device in accordance with an embodiment of the present invention;

[0045] FIG. 2 shows a perspective view of a removable insert in accordance with an embodiment of the present invention for use with a fluid flow control device;

[0046] FIG. 3 shows a perspective view of a removable insert in accordance with another embodiment of the present invention for use with a fluid flow control device;

[0047] FIG. 4 shows an unwrapped view of the removable insert shown in FIG. 3; and

[0048] FIG. 5 shows a plot of the fluid flow characteristics of a fluid flow control device including a variety of removable inserts in accordance with the present invention.

[0049] There are many different industrial situations in which there is a desire to regulate the pressure in a fluid flow stream through a pipe or conduit. In such systems there is an input pressure that may be constant or fluctuating in time and which it is desired to control to a lower target output pressure, which also can be constant or fluctuating. As will now be described, embodiments of the present invention provide devices that are able to provide this control for the fluid flow.

[0050] FIG. 1 shows a cutaway view of a fluid flow control device 1 in accordance with an embodiment of the present invention. The device 1, e.g. a pressure regulator, includes a flange 2 for mounting the device 1 in a section of pipe, e.g. clamped between a joint in the pipework. The device also includes a housing 4 that has a cylindrical wall 6 in which a plurality of valve apertures 8, extending axially through the cylindrical wall 6, are formed. The plurality of valve apertures 8 are each circular in cross section and are arranged in helically extending rows around the circumference of the cylindrical wall 6 of the housing 4.

[0051] The plurality of valve apertures 8 allow fluid to pass from an upstream side 3 of the pipe to a downstream side 5 of the pipe. The flow of the fluid through the plurality of valve apertures 8 is controlled by a cylindrical valve member 10 that is mounted coaxially on the outside of the cylindrical wall 6 of the housing 4, and arranged to move reciprocally in a direction parallel to the main cylindrical axis of the housing 4 and the valve member 10.

[0052] A removable cylindrical plastic insert 12 is mounted coaxially against the inside of the cylindrical wall 6 of the housing 4. FIG. 2 shows a perspective view of the removable cylindrical plastic insert 12.

[0053] The removable cylindrical plastic insert 12 has a cylindrical body 14 in which two helically extending apertures 16 are formed. The helically extending apertures 16 are designed to match the pattern of the plurality of valve apertures 8 formed in the cylindrical wall 6 of the housing 4, such that a discrete number of the plurality of valve apertures 8 are covered by the cylindrical body 14 of the removable cylindrical plastic insert 12 and a discrete number of the plurality of valve apertures 8 are left open by the helically extending apertures 16, i.e. each of the plurality of valve apertures 8 are either fully covered or fully open.

[0054] The removable cylindrical plastic insert 12 also has two lugs 18 arranged diametrically opposite each other on the outside of the cylindrical body 14. The lugs 18 are each arranged to mate with one of the plurality of valve apertures 8 in the cylindrical wall 6 of the housing 4, both in order to help hold the removable cylindrical plastic insert 12 in place during operation of the fluid flow control device 1 and to align the helically extending apertures 16 in the cylindrical body 14 of the removable cylindrical plastic insert 12 with the plurality of valve apertures 8 in the cylindrical wall 6 of the housing 4, i.e. such that each of the plurality of valve apertures 8 are either fully covered or fully open.

[0055] The removable cylindrical plastic insert 12 is 3D printed using ABS such that it is elastically deformable. This allows removable cylindrical plastic insert 12 to be press fit into the housing 4 such that it forms a tight fit against the cylindrical wall 6 of the housing. This tight fit helps the cylindrical body 14 of the removable cylindrical plastic insert 12 to cover the plurality of valve apertures 8 in the cylindrical wall 6 of the housing 4 in a leak-proof manner.

[0056] Operation of the fluid flow control device 1 will now be described with reference to FIGS. 1 and 2.

[0057] Either when the fluid flow control device 1 is in situ in the pipe or before the fluid flow control device 1 is inserted into the pipe, the removable cylindrical plastic insert 12 is press fit into the housing 4 of the fluid flow control device 1, and the two lugs 18 on the outside of the cylindrical body 14 of the removable cylindrical plastic insert 12 are located into two respective valve apertures of the plurality of valve apertures 8, so that the removable cylindrical plastic insert 12 is held in place and the two helically extending apertures 16 in the cylindrical body 14 of the removable cylindrical plastic insert 12 are aligned with the plurality of valve apertures 8 in the cylindrical wall 6 of the housing 4 that are not to be covered.

[0058] It will be seen that with the removable cylindrical plastic insert 12 installed in the fluid flow control device 1, a proportion of the plurality of valve apertures 8 in the cylindrical wall 6 of the housing 4 are covered by the cylindrical body 14 of the removable cylindrical plastic insert 12 and a proportion of the plurality of valve apertures 8 remain open through being aligned with the two helically extending apertures 16 in the cylindrical body 14 of the removable cylindrical plastic insert 12. This results in the number of the plurality of valve apertures 8 that are open being reduced compared to when the removable cylindrical plastic insert 12 is not installed in the fluid flow control device 1.

[0059] The reduction in the number of the plurality of valve apertures 8 that are open thus reduces the fluid flow capacity of the fluid flow control device 1. As the two helically extending apertures 16 in the cylindrical body 14 of the removable cylindrical plastic insert 12 extend along the full length of the plurality of valve apertures 8, the reduction in flow capacity of the fluid flow control device 1 is effective for the full length of travel of the valve aperture 10.

[0060] FIG. 3 shows a perspective view of a removable insert 22 in accordance with another embodiment of the present invention for use with a fluid flow control device, e.g. the one shown in FIG. 1. The removable insert 22 shown in FIG. 3 is very similar to that shown in FIGS. 1 and 2, except that it is made from metal.

[0061] The removable insert 22 of FIG. 3 is laser cut from a sheet of stainless steel and then rolled into a cylinder, such that it has a cylindrical body 24 and two helically extending apertures 26. The removable metal insert 22 has a slit 27 that extends along its length such that it is sprung, i.e. elastically deformable at least in a radial direction.

[0062] FIG. 4 shows an unwrapped view of the removable insert 22 shown in FIG. 3 (i.e. its shape after it has been laser cut but before it has been rolled into a cylinder), superimposed on a typical pattern of the valve apertures 8 in the wall of the cylindrical housing of the fluid flow control device, e.g. as shown in FIG. 1.

[0063] It can be seen form FIG. 4 that the apertures 26 in the removable insert 22 align with the valve apertures 8 in the wall of the cylindrical housing such that when the removable insert 22 is installed in the fluid flow control device the valve apertures 8 are either fully open or fully closed.

[0064] The operation of the removable insert 22 of FIGS. 3 and 4 is very similar to that shown in FIGS. 1 and 2, i.e. its elastic deformability is used to insert it into a fluid flow control device, e.g. as shown in FIG. 1, such that it is held tightly in place against the wall of the cylindrical housing of the fluid flow control device and covers a proportion of the plurality of valve apertures in the wall of the cylindrical housing, leaving a proportion of the plurality of valve apertures open. Again, this acts to reduce the open area of the valve apertures (and thus the flow capacity) of the fluid flow control device (compared to when the removable insert 22 is not installed).

[0065] FIG. 5 shows a plot of the fluid flow characteristics of a fluid flow control device, e.g. as shown in FIG. 1, including a variety of removable inserts in accordance with the present invention, e.g. as shown in FIGS. 1-4. The plot shows the normalised open area of the valve apertures in the fluid flow control device as a function of the axial displacement of the valve member.

[0066] A line of constant gradient 101 shows the operating characteristics of a fluid flow control device without a removable insert fitted. This shows that the normalised open area has a linear relationship with the axial displacement of the valve member.

[0067] A line of constant gradient 102, though reduced by 50% shows the operating characteristics of the fluid flow control device when a first removable insert is fitted. There is still a linear relationship with the axial displacement of the valve member, but at each value of the valve member displacement the normalised open area is reduced by 50% compared to when the removable insert is not installed in the fluid flow control device.

[0068] A polynomial line 103 shows the operating characteristics of the fluid flow control device when a second removable insert is fitted (i.e. instead of the first removable insert). The normalised open area has a polynomial relationship with the displacement of the valve member and with the maximum flow capacity, i.e. when the valve member is fully open, being 50% of the maximum normalised open area when the removable insert is not installed in the fluid flow control device.

[0069] The removable inserts shown in FIGS. 1 to 4 have the 50% polynomial relationship shown by the polynomial line 103 in FIG. 5.

[0070] An exponential line 104 shows the operating characteristics of the fluid flow control device when third removable insert is fitted (i.e. instead of the first and second removable inserts). The normalised open area of the valve apertures has an exponential relationship with the displacement of the valve member and with the maximum normalised open area, i.e. when the valve member is fully open, being 50% of the maximum normalised open area when the removable insert is not installed in the fluid flow control device. This exponential relationship means that for a given displacement of the valve member this results in the same percentage difference in the normalised open area of the valve apertures.

[0071] It can be seen from the above that in at least preferred embodiments, the fluid control flow device and the removable insert of the present invention provide a device for controlling the flow in a conduit in which the open area of the valve apertures (and thus the flow capacity) can be adjusted in a simple and cost effective manner. Multiple designs of the removable insert may be provided to suit different operating requirements so that only a single design for the design and the housing thereof (in which the multiple valve apertures are formed) may need to be manufactured. Once a flow control device is installed, the removable insert may be replaced with a different design of the removable insert so that the proportion of the valve apertures blocked by the removable insert may be changed, e.g. to increase or decrease the open area of the valve apertures (and thus the flow capacity) of the device. The housing is able to provide a structural, e.g. pressure loaded, component of the device, such that it is not necessary for the removable insert to have any pressure loading or structural capacity; the removable insert is preferably simply designed to block some of the multiple valve apertures, with the pressure loading being taken by the strength of the housing.

[0072] While a couple of particular embodiments have been described above with reference to the Figures, those skilled in the art will appreciate that any number of variations and alternatives may exist within the scope of the present invention. For example, the apertures in the removable insert may be different sizes and/or shapes, e.g. if the open area of the valve apertures and/or its relationship with the displacement of the valve member is desired to be changed. It will be appreciated that with multiple different designs of the removable insert the flow capacity and its characteristics may be tuned as desired for different particular operations.

[0073] Furthermore, the removable insert may be mounted on the outside wall of the housing of the fluid flow device, with the valve member being mounted on the inside wall of the housing of the fluid flow device.