Ball Segment Valve with Overlapping Check Valve
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Solution Overview
Problem
Existing valve arrangements, particularly those combining ball and check valves, are inadequate for positive energy isolation and backflow prevention in industrial applications, especially when handling flammable fluids, due to insufficient sealing force and inefficiencies in space, weight, and cost.
Innovation Solution
A spring-assisted, dual plate check valve integrated with a ball segment valve, where a flapper door overlaps the ball segment, creating an isolated chamber that can be pressurized with a non-flammable fluid to ensure robust sealing and maintain a compact, cost-effective design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a check valve is used alone for backflow prevention, then directional flow control is achieved, but sealing force is insufficient for positive energy isolation
Solution Approach 1:
The patent combines a ball valve and check valve into a single integrated valve assembly. The ball valve provides reliable sealing for positive energy isolation, while the check valve provides backflow prevention. The two valve mechanisms share a common body and outlet, creating a unified device that delivers both functions simultaneously rather than requiring separate valves.
Solution Approach 2:
The integrated valve assembly performs multiple functions: the ball valve component handles positive closure and isolation, the check valve component handles backflow prevention, and together they provide double-block sealing capability. This multi-functional design eliminates the need for separate isolation and backflow prevention devices.
2Reliability
If separate ball valve and check valve are installed adjacent to each other, then redundant sealing is achieved, but space, weight and cost increase
Solution Approach 1:
The patent merges two separate valve functions into a single compact assembly. The ball valve and check valve share a common body structure and outlet, with the check valve positioned adjacent to the ball valve within the same housing. This integration dramatically reduces the space required compared to installing two separate valves side-by-side while maintaining the double-block sealing capability.
Solution Approach 2:
The check valve is positioned within the same housing as the ball valve, with components nested or adjacent to each other in a space-efficient arrangement. The check valve seat and flapper are integrated into the ball valve body structure, creating a compact nested configuration that minimizes overall valve assembly dimensions.
3Reliability
If a ball valve is used for double block and bleed, then positive isolation is achieved, but backflow prevention capability is insufficient
Solution Approach 1:
The integrated valve assembly combines the ball valve's superior isolation capability with the check valve's backflow prevention function. The ball valve provides reliable positive closure for double-block and bleed applications, while the check valve adds automatic backflow prevention. The merged design delivers both isolation and backflow protection in a single device.
Solution Approach 2:
The valve assembly is designed to perform multiple functions: the ball valve component provides isolation and double-block capability, while the check valve component provides automatic backflow prevention. This multi-functional design allows a single valve assembly to replace what would traditionally require separate isolation and backflow prevention devices.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides effective positive isolation and directional control, enabling safe maintenance operations by ensuring redundant closure members within a compact package, offering space, cost, and weight savings over single valves while preventing leaks and backflow.
Implementation Method 1
spring-assisted, dual plate check valve
Implementation Method 2
isolated chamber that can be pressurized with a non-flammable fluid to ensure robust sealing
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A valve apparatus (10) including a check valve (14) and a ball segment valve (12) is provided within a fluid system (100) for handling a flammable working fluid. The valve apparatus (10) is arranged such that flapper doors (32, 34) of the check valve (14) longitudinally overlaps a ball segment (30) of the ball segment valve (12) when each are in respective open positions such that the valve apparatus (10) maintains a face-to-face dimension of a standard ball valve. The valve apparatus (10) can thus provide positive isolation and directional fluid control in a congested fluid system (100) with space savings over single valves. An isolated chamber is defined between the flapper doors (32, 34) and the ball segment (30) when each is in a respective closed position. A non-flammable fluid (F) is injected into the isolated chamber (26) to urge the flapper doors (32, 34) and ball segment (30) toward the closed positions to thereby provide a safe environment for performing maintenance operations on downstream fluid components (104).