Project Description:
Baltimore Gas & Electric (BGE) operates over 600 regional regulator stations throughout Maryland to reduce natural gas pressure from transmission levels of 300 psig down to distribution levels around 90 psig. The existing configuration, comprising two regulators and multiple manual valves, puts human error as a greater factor during maintenance. The current station design also occupies a footprint of over 300 square feet, increasing installation and property costs. In response to these challenges, this project presents a redesigned regulator station featuring a hybrid bypass system with a third regulator and electronically actuated valves, aimed at increasing system safety, reducing the need for manual operation, and decreasing the overall station footprint.
The hybrid bypass system utilizes three Mooney Flowgrid regulators serving as the monitor, feeder, and bypass. By carefully staggering their setpoints (95, 92, and 93.5 psig respectively), the system ensures uninterrupted gas delivery during maintenance, inspection, or regulator failure. This design eliminates the need to manually close and open ball valves during reconfiguration by instead using a motorized actuation system, consisting of a clutch, gearbox, and 24V DC motor, all powered by a portable generator. The regulator system is supported by 4” ASTM A53 steel piping with ASME standard fittings to simplify assembly and ensure long-term durability. The final CAD layout as modeled in Solidworks compresses the station’s footprint to 247 square feet, reducing the footprint by 27%.
The physical layout and valve actuation were prototyped using a low-fidelity system to compare the new configuration against BGE’s original setup. Valve sequencing trials revealed that the electronic system completed transitions 28% faster than manual ball valve operation. While the hybrid design includes additional piping and valves, which adds some complexity, the overall system proved more efficient and safer during reconfiguration procedures. These findings were supported by time trials and physical handling of the prototype.
