Inflatable Balloon Valve Isolation Tool
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Solution Overview
Problem
In gas treatment and production facilities, the removal and inspection of relief valves often result in inconvenient and costly system shutdowns due to gas leakage, especially when block valves do not achieve 100% shut-off, leading to substantial downtime and expense.
Innovation Solution
A method and apparatus using an inflatable balloon to temporarily seal gas flow ducts, allowing for the isolation and removal of relief valves without shutting down the system, by inserting an un-inflated balloon upstream or downstream of the valve and inflating it to block gas flow, using a tubular isolation tool with a high-pressure source to fill the duct segment and prevent leaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If block valves are used to isolate relief valves for inspection or removal, then valve maintenance can be performed, but gas leakage occurs due to incomplete shut-off (not achieving 100% shut-off)
Solution Approach 1:
The patent introduces a balloon as an intermediary sealing element that is inserted into the duct upstream of the relief valve and inflated to create a complete gas-tight seal. This balloon acts as a mediator between the block valve and the relief valve, ensuring 100% shut-off capability that the block valve alone cannot achieve, thereby eliminating gas leakage during valve maintenance operations
Solution Approach 2:
The isolation system is divided into two functional components: the block valve for mechanical isolation and the balloon for sealing. This segmentation allows each component to perform its specific function optimally - the block valve provides structural isolation while the balloon provides the actual gas-tight seal, together resolving the leakage problem
2Reliability
If the parent system is shut down to prevent gas leakage during relief valve removal, then safety is improved, but substantial downtime and expense occur
Solution Approach 1:
The balloon is inserted and inflated in advance before the relief valve is removed, creating a sealed isolation zone upstream of the valve. This preliminary sealing action ensures that when the relief valve is removed for maintenance, the gas is already contained and cannot leak, allowing the rest of the system to continue operating without shutdown while maintaining safety
Solution Approach 2:
The balloon serves as a mediator that creates a controlled isolation environment, allowing the relief valve to be removed and maintained without requiring the entire parent system to be shut down. The balloon mediates between the need for valve access and the need for system continuity, enabling maintenance while the system remains operational downstream
3Reliability
If conventional shutdown procedures are used for relief valve maintenance, then complete gas isolation is achieved, but substantial expense and downtime result
Solution Approach 1:
The balloon acts as a portable, deployable intermediary sealing device that can be quickly inserted and inflated to create complete gas isolation at the specific location where the relief valve is to be maintained. This localized sealing approach replaces the need for system-wide shutdown procedures, achieving the same isolation reliability while allowing the rest of the system to continue producing
Solution Approach 2:
The isolation is applied locally at the specific duct section where the relief valve is located, rather than shutting down the entire system. The balloon creates a localized seal with 100% gas-tightness at the maintenance point, allowing different parts of the system to have different operational states - isolated where needed, operational elsewhere
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
Enables efficient inspection, repair, and replacement of relief valves in as little as 15-30 minutes without interrupting the duct system, significantly reducing downtime and costs compared to conventional methods which typically require several days of shutdown.
Implementation Method 1
inserting an un-inflated balloon upstream or downstream of the valve and inflating it to block gas flow
Implementation Method 2
using a tubular isolation tool with a high-pressure source to fill the duct segment
Data Source
AI summary
A leaking block valve isolation tool for insertion through a vent duct and blocking valve of a gas flow duct. The isolation tool includes an outer tube having proximal and distal ends, the outer tube having a diameter sized to extend through the vent duct and blocking valve. An inner tube having proximal and distal ends is arranged coaxially with and movable within the outer tube. An inflatable balloon is attached to the distal end of the inner tube, wherein the isolation tool outer tube is insertable through the vent duct to an opening in the gas flow duct. The inner tube is slidably insertable through the outer tube until the balloon is situated within a bore formed through the gas flow duct and is inflatable therein to block any gas leak through the gas flow duct.