Patent Application
20140116520
The present disclosure relates generally to a fuel system, and more particularly, to a fuel system having a dual fuel pressure regulator.
Dual fuel engines are well known in the art and combust a mixture of two different types of fuel. For example, a particular dual fuel engine can combust a mixture of a liquid fuel (e.g., diesel fuel) and a gaseous fuel (e.g., natural gas). By combusting two different types of fuel, advantages of both fuels (e.g., efficiency, power, emissions, cost, etc.) can be realized.
In order to properly control performance of a dual fuel engine, the pressures and/or flow rates of the two different fuels into the engine should be tightly regulated. Historically, the pressures and/or flow rates of the fuels have been regulated independently, for example by way of a variable displacement liquid fuel pump and by way of a gas vent. The variable displacement liquid fuel pump, however, may be too expensive and/or complex for some applications. In addition, venting of the gaseous fuel may be undesirable in some areas. Finally, it may be desirable to link the pressures and/or flow rates of the two fuels in some operations, such that desired ratios of the fuels may be provided.
One way to control the pressures and flows of a dual fuel system is described in U.S. Pat. No. 6,298,833 issued to Douville et al. on Oct. 9, 2001 (the '833 patent). In particular, the '833 patent describes a system for delivering diesel fuel and gaseous fuel through an injector into an engine. The system employs a pressure balancing device having a first chamber in fluid communication with a supply of the diesel fuel and with the injector, a second chamber isolated from the first chamber and in fluid communication with a supply of the gaseous fuel and the injector, and a piston separating the first and second chambers. The piston is movable to maintain a pressure of the diesel fuel a fixed amount higher than a pressure of the gaseous fuel. In addition, a position of the piston is sensed and used to control a diesel fuel pump, thereby maintaining the pressures of both the diesel fuel and the gaseous fuel within a desired range.
While the system of the '833 patent may adequately control diesel and gaseous fuel pressures for some applications, it may still be less than optimal. In particular, the system may not provide for a diesel only mode of operation, or allow for independent control of diesel and gaseous fuel pressures. These deficiencies may reduce the capability and functionality of the associated engine.
The disclosed fuel system and pressure regulator are directed to overcoming one or more of the problems set forth above and/or other problems of the prior art.
In one aspect, the present disclosure is directed to a pressure regulator. The pressure regulator may include a body, a cavity formed in the body, a first inlet port in fluid communication with a first end of the cavity, a first outlet port in fluid communication with the first end of the cavity, and a second inlet port in fluid communication with a second end of the cavity. The pressure regulator may also include a valve element movable based on a pressure difference between the first and second inlet ports to any position between a first fully open position at which fluid is allowed to flow from the first inlet port through the first outlet port substantially unrestricted by the valve element, to a second fully restricted position at which fluid flow from the first inlet through the first outlet port is blocked.
In another aspect, the present disclosure is directed to a fuel system. The fuel system may include a first supply of liquid fuel, a second supply of gaseous fuel, and a fuel injector configured to receive liquid and gaseous fuel from the first and second supplies. The fuel system may also include a pressure regulator in parallel fluid communication with the first and second supplies. The pressure regulator may be configured to selectively regulate a pressure of the liquid fuel based on a pressure of the gaseous fuel, and to selectively block pressure regulation of the liquid fuel by the gaseous fuel.
In yet another aspect, the present disclosure is directed to a method of regulating fuel pressures for an engine. The method may include directing pressurized liquid fuel from a first supply to an injector of the engine, and directing gaseous fuel from a second supply to the injector in parallel with the liquid fuel. The method may also include selectively returning a varying amount of the liquid fuel back to the first supply based on a pressure of the gaseous fuel, and selectively regulating a pressure of the liquid fuel independently of the pressure of the gaseous fuel.
GFSC 12 may include components that cooperate to deliver natural gas from a supply 20 to pressure regulator 18 and to injector 16 in parallel. These components may include, for example, a pump 22, a high-pressure accumulator 24, a metering valve 26, and a low-pressure accumulator 28. Pump 22 may be connected to supply 20 by way of a passage 30, and to high-pressure accumulator 24 by way of a passage 32. Metering valve 26 may be connected between high- and low-pressure accumulators 24, 28 by way of passages 34 and 36. Low-pressure accumulator 28 may be connected to pressure regulator 18 and to injector 16 by way of passages 38 and 40, respectively. Pump 22 may be configured to draw natural gas (or otherwise receive natural gas) from supply 20 via passage 30, and push the natural gas through passage 32 into high-pressure accumulator 24. The natural gas may then flow through passage 34, metering valve 26, and passage 36 to low-pressure accumulator 28 at a rate and/or with a pressure affected by an adjustable restriction of metering valve 26. From low-pressure accumulator 28, the natural gas may be directed in parallel to both pressure regulator 18 and injector 16 via passages 38 and 40.
Supply 20 may embody a cryogenic tank configured to hold the natural gas in a liquefied state. In the exemplary embodiment, supply 20 is an insulated tank that maintains a temperature of the natural gas below a boiling temperature of about −165° C. It is contemplated that supply 20 may be provided with conventional equipment for handling liquefied natural gas (LNG), for example chillers, heaters, circulators, ventilators, etc., as desired.
Pump 22 may be any type of pump known in the art for handling natural gas in its liquid state (LNG) and/or gaseous state. In particular, at any point between supply 20 and high-pressure accumulator 24 (e.g., upstream and/or downstream of pump 22), the LNG may gasify. In the disclosed exemplary embodiment, the LNG is gasified downstream of pump 22 and pump 22 is configured to handle only LNG. In this embodiment, pump 22 includes a fixed displacement pumping device 42 (e.g., a piston type, diaphragm type, or centrifugal type pump) that is powered by a variable speed drive 44 (e.g., a hydraulic pump 44a driven by the engine described above and connected to a hydraulic motor 44b in closed-loop fashion, motor 44b being mechanically connected to pumping device 42). With this configuration, although the displacement of pumping device 42 is fixed, the output of pump 22 may still be varied by adjusting the speed of drive 44. The speed of drive 44 may be adjusted by changing an input speed of hydraulic pump 44a and/or changing a displacement of hydraulic pump 44a or hydraulic motor 44b. It is contemplated that other types of pumps may alternatively be utilized to push natural gas through GFSC 12, if desired, for example a variably displacement pump.
Each of high- and low-pressure accumulators 24, 28 may embody pressure vessels configured to store pressurized natural gas for future use by injector 16. As natural gas in passages 32 and 36 exceeds pressures of high- and low-pressure accumulators 24, 28, respectively, the natural gas may flow into high- and low-pressure accumulators 24, 28. Because the natural gas therein is compressible, it may act like a spring and compress as more natural gas flows into high- and low-pressure accumulators 24, 28. When the pressure of the natural gas within passages 34, 38, and/or 40 drops below the pressures of high- and low-pressure accumulators 24, 28, the compressed natural gas may expand and exit high- and low-pressure accumulators 24, 28. It is contemplated that high- and low-pressure accumulators 24, 28 may alternatively embody membrane/spring-biased or bladder types of accumulators, if desired.
In the disclosed embodiment, high-pressure accumulator 24 may have a higher-pressure, as compared to low-pressure accumulator 28. Specifically, high-pressure accumulator 24 may be configured to accumulate natural gas having a pressure in the range of about 15-40 MPa, while low-pressure accumulator 28 may be configured to accumulate natural gas having a pressure that is about 1-25 MPa lower. It is contemplated, however, that other pressures may alternatively be accommodated by high- and/or low-pressure accumulators 24, 28, if desired. It is also contemplated that high- and low-pressure accumulators 24, 28 may have about the same volumes or different volumes. For example, high-pressure accumulator 24 may be significantly larger than low-pressure accumulator 28, if desired.
During operation of GFSC 12, the pressures of high- and/or low-pressure accumulators 24, 28 may be monitored. For example, one or more pressure sensors 46 may be associated with one or both of high- and low-pressure accumulators 24, 28 and configured to generate signals indicative of the pressures thereof. The signals from pressure sensors 46 may be directed to a controller 48 for further processing.
Metering valve 26 may embody an electronically controlled valve element that is movable to any position between an open flow-passing position and a closed flow-blocking position. Because high-pressure accumulator 24 may generally have a higher-pressure than low-pressure accumulator 28, moving the valve element of metering valve 26 toward the flow-passing position may result in a greater flow of natural gas into low-pressure accumulator 28. For a given consumption rate of natural gas by injector 16, a greater flow of natural gas through metering valve 26 may generally result in an increase in pressure within low-pressure accumulator 28. The valve element of metering valve 26 may be moved between the flow-passing and flow-blocking positions in response to a command signal from controller 48.
LFSC 14 may include components that cooperate to deliver diesel from a supply 50 to pressure regulator 18 and to injector 16 in parallel. These components may include, for example, a transfer pump 52, a metering valve 54, a high-pressure pump 56, and an accumulator 58. Transfer pump 52 may be connected to supply 50 by way of a passage 60, and to metering valve 54 by way of a passage 62. High-pressure pump 56 may be connected between metering valve 54 and accumulator 58 by way of passages 64 and 66. Accumulator 58 may be connected to pressure regulator 18 and to injector 16 by way of passages 68 and 70, respectively. A return passage 72 may connect pressure regulator 18 to supply 50. Transfer pump 52 may be configured to draw diesel (or otherwise receive diesel) from supply 50 via passage 60, and push the diesel through passage 62, metering valve 54, and passage 60 into high-pressure pump 56. The diesel may flow through metering valve 54 at a rate and/or with a pressure affected by a restriction of metering valve 54. From high-pressure pump 56, the diesel may be directed through accumulator 58 to both pressure regulator 18 and injector 16 in parallel via passages 68 and 70. Any diesel intentionally or inadvertently leaked from pressure regulator 18 may be directed back to supply 50 via passage 72. In some applications, a fixed or variable restriction 74 may be placed within passage 72 to allow monitoring of a rate of return of diesel fuel using a pressure sensing device (not shown). This information may be useful in limiting an amount of excess pumping, while ensuring adequate desel fuel delivery to regulator 18 in order to maintain desired pressure control. The information may also be used to monitory diesel fuel delivery and identify fault conditions.
Supply 50 may embody a conventional tank configured to hold diesel. It is contemplated that supply 50 may be provided with conventional equipment for handling diesel, for example filters, separators, circulators, ventilators, etc., as desired.
Transfer pump 52 may be configured to provide low-pressure feed to high-pressure pump 56. In one exemplary embodiment, transfer pump 52 may be an electrically powered diaphragm pump that is selectively turned on and off (i.e., cycled) based on a pressure within LFSC 14. It is contemplated, however, that transfer pump 52 may alternatively be another type of pump known in the art, if desired.
Metering valve 54, like metering valve 26, may include an electronically controlled valve element movable to any position between an open flow-passing position and a closed flow-blocking position. Because metering valve 54 may be located at an inlet of high-pressure pump 56, metering valve 54 may function to regulate an output of high-pressure pump 56. That is, by moving the valve element of metering valve 54 toward the flow-passing position, high-pressure pump 56 may be capable of drawing in, pressurizing, and discharging a greater flow rate of diesel into accumulator 58. For a given consumption rate of natural gas by injector 16, a greater discharge rate of diesel from high-pressure pump 56 may generally result in an increase in pressure within accumulator 58. The valve element of metering valve 54 may be moved between the flow-passing and flow-blocking positions in response to a command signal from controller 48.
High-pressure pump 56 may be configured to receive the low-pressure feed from transfer pump 52 (i.e., by way of metering valve 54), and increase the pressure of the diesel to, in some embodiments, about 100 MPa. In the disclosed exemplary embodiment, high-pressure pump 56 is a fixed-displacement, piston-type pump. It is contemplated, however, that high-pressure pump 56 may alternatively be any other type of pump known in the art, for example a fixed- or variable-displacement piston-pump, centrifugal pump, or another type of pump that is electrically and/or mechanically driven by the engine described above. It is also contemplated that, if high-pressure pump 56 were to be replaced with a variable-displacement pump, it may be possible to omit metering valve 54 from LFSC 14, if desired.
Accumulator 58 may embody a pressure vessel filled with a compressible gas that is configured to store pressurized diesel for future use by injector 16. The compressible gas may include, for example, nitrogen, argon, helium, or another appropriate compressible gas. As diesel in passage 66 exceeds a pressure of accumulator 58, the diesel may flow into accumulator 58. Because the gas therein is compressible, it may act like a spring and compress as the diesel flows into accumulator 58. When the pressure of the diesel within passage 70 drops below the pressure of accumulator 58, the compressed gas may expand and urge the diesel from within accumulator 58 to exit. In general, a pressure of diesel within accumulator 58 may be maintained higher than a pressure of natural gas within high- and low-pressure accumulators 24, 28. For example, the diesel pressure may be maintained about 5 MPa higher than the natural gas pressure during normal operation (e.g., within a range of about 20-40 MPa). And during a diesel-only mode of operation, as will be described in more detail below, the diesel pressure may be raised to about 80-100 MPa within accumulator 58. It is contemplated that accumulator 58 may alternatively simply be a tank or another type of accumulator such as a membrane/spring or bladder type of accumulator, if desired.
During operation of LFSC 14, the pressures of accumulator 58 and/or return passage 72 may be monitored. For example, one or more pressure sensors 46 may be associated with one or both of accumulator 58 and return passage 72 (e.g., at a location upstream of restriction 74) and configured to generate signals indicative of the pressures thereof The signals from pressure sensors 46 may be directed to controller 48 for further processing.
Pressure regulator 18 may be an assembly of components that function together to regulate pressures within fuel system 10. These components may include, among other things, a body 76 having a primary cavity 78 and a secondary cavity 80 formed therein. Primary cavity 78 may be configured to selectively pass a flow of diesel at a first end 86 from a first inlet port 82 to an outlet port 84, and to receive natural gas at an opposing second end 90 by way of an inlet port 88. A valve element 92 may be disposed within cavity 78 to separate first and second ends 86, 90. Valve element 92 may include an internal passage 94 that selectively connects first inlet port 82 with outlet port 84 based on a position of valve element 92. Secondary cavity 80 may be configured to receive an actuator 96, for example a hydro-mechanical actuator (such as a hydraulic piston) or an electronic actuator (such as a solenoid) that exerts a biasing force on valve element 92 to move valve element 92 toward first end 86 of cavity 78. A spring 98 may exert an additional biasing force on valve element 92 that works in concert with the biasing force of electronic actuator 96. An end stop 100 may be disposed within cavity 78 at first end 86 and configured to be selectively engaged by an axial end of valve element 92 at passage 94, thereby blocking flow through passage 94. In the embodiment of
An alternative fuel system 200 is shown in
LFSC 202, like LFSC 14, may include supply 50, transfer pump 52, metering valve 54, high-pressure pump 56, and accumulator 58. However, rather than directing diesel to pressure regulator 18 and injector 16 in parallel, accumulator 58 may instead send diesel to only pressure regulator 18. In addition, LFSC 202 may include a second accumulator 206 that receives diesel from pressure regulator 18 (i.e., from a second outlet port 208) and discharges diesel toward injector 16 via passage 70.
Pressure regulator 204 of
Another alternative fuel system 300 is shown in
Pressure regulator 302 of
Another alternative fuel system 400 is shown in
LFSC 402, like LFSC 202, may include supply 50, transfer pump 52, metering valve 54, high-pressure pump 56, and accumulator 206. However, accumulator 58 may be omitted from LFSC 402. That is, high-pressure pump 56 may discharge directly into passage 68, rather than directing diesel into accumulator 58 via passage 66.
Pressure regulator 404 of
Additionally, fuel system 400 may include a pressure relief circuit 406. Pressure relief circuit 406 may include, among other things, a supply passage 408, a return passage 410, and a check valve element 412 disposed at a junction of supply and return passages 408, 410. Supply passage 408 may extend from a location downstream of transfer pump 52 to check valve element 412, while return passage 410 may extend from check valve element 412 to supply 50. Check valve element 412 may be in communication with accumulator 206, supply passage 408, and return passage 410. Based on a pressure difference between accumulator 206, supply passage 408, and return passage 410, check valve element 412 may selectively move from a flow-blocking position toward a flow-passing position at which fluid from within accumulator 206 and/or within supply passage 408 is relieved back to supply 50 via return passage 410. It is contemplated that, although pressure relief circuit 406 is shown only in combination with fuel system 400, pressure relief circuit 406 could likewise be used in conjunction with any of fuel systems 10, 200, and/or 300, if desired.
The disclosed fuel systems and pressure regulators find potential application in any dual-fuel power generation application. The disclosed fuel systems and pressure regulators may help provide for responsive simultaneous control over diesel and natural gas pressures. In addition, the disclosed fuel systems and pressure regulators may help provide for operation in a diesel only mode of operation. Operation of fuel system 10 will now be described.
Referring to
Pressure regulator 18 may be configured to regulate a pressure of the diesel directed to injector 16 based on a pressure of the natural gas also directed to injector 16. In particular, with both fuels acting in opposite directions on about the same surface areas of valve element 92, valve element 92 may be biased by a difference in pressures toward the lower-pressure fuel. For example, as natural gas pressures begin to rise (relative to diesel pressures), a greater force may be generated that functions to push valve element 92 toward first end 86 (i.e., leftward in
The bias of spring 98 and/or actuator 96 may affect how much pressure difference is allowed between the diesel and natural gas. In particular, the spring bias, together with the actuator bias may offset the balance between forces acting on valve element 92. For example, in order to move valve element 92 to a less restricting position (i.e., rightward in
In some embodiments, the bias of actuator 96 may be adjusted so as to vary the pressure difference between the diesel and natural gas. In particular, controller 48 may be configured to vary an amplitude and/or frequency of the command signal sent to actuator 96 to thereby adjust the bias of actuator 96. In this manner, the difference in fuel pressures may be adjusted to accommodate different modes of operation.
The natural gas pressure within fuel system 10 may be adjusted in different ways. For example, the operation of pump 22 may be adjusted (e.g., the displacement and/or speed of pump 44a and/or motor 44b may be adjusted) to thereby vary a pressure and/or flow rate of natural gas being discharged into high-pressure accumulator 24. In addition or alternatively, the restriction placed the natural gas flow between high- and low-pressure accumulators 24, 28 may be varied by metering valve 26. By placing a higher restriction on the flow of natural gas between high- and low-pressure accumulators 24, 28, a greater pressure drop between high- and low-pressure accumulators 24, 28 may be achieved. The opposite may also be true. In this manner, natural gas pressure may be adjusted without having to vent natural gas to the atmosphere.
The diesel pressure within fuel system 10 may also be adjusted in different ways. As described above, the offset or difference between natural gas pressure and diesel pressure may be adjusted through the use of actuator 96. During normal operations, diesel pressure may always be somewhat higher than natural gas pressure, and the output of high-pressure pump 56 may be such that the demand of injector 16 is satisfied, the desired pressure difference is maintained, and some diesel is returned (i.e., leaks back) to supply 50 via regulator 18 and return passage 72. This control may be facilitated by controller 48 via feedback from the various pressure sensors 46. Alternatively, actuator 96 may be commanded to extend a maximum amount (i.e., to move leftward in
Fuel system 10 may be capable of operation in a diesel only mode. This mode may be desirable when, for example, the supply of natural gas has been depleted, during startup, or when a failure has occurred within GFSC 12. When any of these situations is detected by controller 48, for example by way of pressure sensors 46, actuator 96 may again be commanded by controller 48 to extend the maximum amount (i.e., to move leftward in
Operation of fuel system 200 of
Operation of fuel system 300 may also be similar to operation of fuel system 10 described above. However, in contrast to fuel system 10, actuator 96 of fuel system 300 may be a normally closed actuator. That is, actuator 96 may be biased toward valve element 92 by spring 304, and a command signal from controller 48 may result in reverse movement of actuator 96. In this configuration, during an electrical failure of fuel system 300, actuator 96 may be forced to its maximum extended position against valve element 92 by spring 304, thereby providing for the diesel only (i.e., limp home) capability during the electrical failure.
In addition, spring 304 of fuel system 300 may provide pressure relief functionality for LFSC 14. In particular, during a situation when spring 304 is forcing valve element 92 to its maximum extended position, a significant pressure spike within LFSC 14 may cause valve element 92 to move in reverse direction and compress spring 304 until some amount of diesel escapes pressure regulator 18 and leaks back to supply 50. This leakage may result in a reduced pressure within LFSC 14 and provide some component protection against damaging extremes.
Fuel system 400 may have all of the same functionality, modes of operation, and protection of fuel systems 10, 200, and 300, with additional pressure relief capability. In particular, when a pressure of diesel within accumulator 206 and/or supply passage 408 exceeds a pressure within return passage 410 by an amount greater than a spring bias of check valve element 412, check valve element 412 may move from a flow-blocking position toward a flow-passing position at which fluid from within accumulator 206 and/or within supply passage 408 is relieved back to supply 50 via return passage 410. This capability may provide extra protection to transfer pump 52, metering valve 54, high-pressure pump 56, pressure regulator 18, and/or fuel injector 16.
It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed fuel system and regulator. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the disclosed fuel system and regulator. It is intended that the specification and examples be considered as exemplary only, with a true scope being indicated by the following claims and their equivalents.
