Mitigating Immediate Pressure Drop in Storage Tank Apparatus Post Valve Malfunction
On our platform, we specialize in crafting top-notch valve solutions that boost the safety and efficiency of industrial systems. Recently, a client approached us with a pressing issue concerning hydrogen gas management in their process. They needed a control system to prevent damages caused by sudden depressurization due to valve malfunction. We came up with a solution using our PCV-XXX and associated components to meet their requirements. Here's a breakdown of the system and the challenges we addressed:
The Client's Dilemma
The client handles hydrogen systems that require accurate flow and pressure control for smooth operation. Their predicament was that they required a solution capable of maintaining a pressure differential of 0.5 barg between two points (P1 and P2), along with supporting flow rates between 0 and 1200 LPM. The starting pressure before the valve (P1) ranges from 1 to 50 barg, while the desired pressure after the valve (P2) should ideally be between P1 - 0.2 to 0.5 barg. However, in the event of a system failure, specifically the failure of the PCV-531 valve, they were worried about a rapid pressure drop leading to substantial damage.
Our Solution for the Gas Dilemma
To safeguard against pressure loss and preserve overall system integrity, we proposed a solution that combined a differential pressure regulator with an automatic response mechanism in case of failure. Let's see how this solution works:
Objectives
- Maintain controlled operation under normal conditions, keeping a pressure differential of 0.5 barg between P1 and P2, with a flow rate of 0-1200 LPM.
- In the event of system malfunction, such as abnormal pressure loss, automatically adjust the PCV-XXX opening to prevent a rapid drop in the P1 side pressure and shield the equipment.
- Provide emergency shut-off protection in case P1 falls below 25 barg, ensuring safety for the storage tank.
Equipment & Functions
Pressure Switch (PSW)
- Set Pressure: 25 barg (Adjustable by the End-User)
- Function: When P1 drops below 25 barg, the PSW sends an urgent signal to immediately close the ESV, shutting off downstream flow and preventing further pressure loss.
- Location: At the storage tank outlet, near the ESV.
Emergency Shutoff Valve (ESV)
- Type: Energized to Close (ESD - Energized Shut Down)
- Function: When PSW is triggered (P1 drops below 25 barg), the PSW sends a signal, and the ESV immediately closes, putting a stop to downstream flow to inhibit further pressure loss.
- Usual Condition (P1 ≥ 25 barg): The ESV remains open, allowing the fluid to flow.
- The ESV only closes when it receives the PSW trigger signal, ensuring proper operation regardless of power interruptions.
Pneumatic Control Valve (PCV-XXX)
Control Method: Regulates based on the pressure differential between P1 and P2
Set Pressure Differential: 0.5 barg
Control Logic:
- When P1-P2 = 0.5 barg, PCV-XXX maintains its current opening, keeping the flow constant.
- When P1-P2 exceeds 0.5 barg, PCV-XXX increases its opening, releasing pressure and reducing P1-side pressure.
- When P1-P2 falls below 0.5 barg, PCV-XXX decreases its opening, limiting flow and preserving P1-side pressure.
Differential Pressure Transmitter (DPT)
Monitoring Points: P1 and P2
Set Value: 0.5 barg
Function:
- Monitors the pressure differential (P1-P2) and determines the opening of the PCV-XXX.
- When P1-P2 exceeds 0.5 barg, the PCV-XXX's opening increases;
- when P1-P2 drops below 0.5 barg, the PCV-XXX's opening decreases.
How This Solution Works
Under normal operations, the system maintains a stable flow and pressure, ensuring that the differential pressure between P1 and P2 stays within acceptable limits. However, in the event of a failure, such as the PCV-531 malfunctioning, our solution adjusts the valve opening to prevent sudden depressurization. If P1 drops below the critical 25 barg threshold, the PSW triggers the ESV to close, preventing further damages and ensuring the system's safety.
Conclusion
Our custom solution combines our PCV-XXX, PSW, and ESV to guarantee smooth, dependable operation and protection against abrupt pressure loss. By leveraging advanced control and monitoring technology, we addressed the client's requirements and provided a system that shields their equipment and boosts operational reliability.
Facing similar challenges or in need of customized valve solutions? Don't hesitate to connect with us. We're on standby to assist you in optimizing your system's performance and safeguarding its safety and efficiency.
In response to the client's need for a control system to manage hydrogen gas effectively while preventing damages caused by sudden depressurization due to valve malfunction, we developed a solution integrating a differential pressure regulator and an automatic response mechanism. This solution, consisting of a Pressure Switch (PSW), Emergency Shutoff Valve (ESV), Pneumatic Control Valve (PCV-XXX), and Differential Pressure Transmitter (DPT), maintains controlled operation under normal conditions and safeguards against pressure loss in case of system failure. By utilizing this technology in the manufacturing industry, we can ensure finance-efficient energy consumption in hydrogen systems while enhancing safety and technology advancement.
