Bidirectional Sphere Prover Reducer for Launch Failure
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Solution Overview
Problem
Bidirectional sphere provers with horizontal launch tubes often fail to launch the sphere successfully during the first water draw attempt, especially in larger pipe diameters, due to issues with concentricity and abrupt angle of contact, leading to delays and potential loss of business.
Innovation Solution
The development of an elongate concentric fabricated reducer with a more gradual angle of contact, designed to be twice as long as the diameter of the downstream piping, is used in horizontal type prover designs to improve sphere launch consistency and success rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a short reducer with abrupt angle of contact is used in horizontal launch tubes, then the device complexity is reduced, but the sphere launch reliability deteriorates due to concentricity issues and launch failures
Solution Approach 1:
The patent changes the geometric parameters of the reducer by making it elongate (length at least twice the downstream pipe diameter) and providing a gradual angle of contact. This parameter change resolves the concentricity alignment issues between the launch tube and downstream piping, ensuring reliable sphere launch while maintaining a relatively simple single-piece fabricated structure.
2Reliability
If an elongate concentric fabricated reducer with gradual angle of contact is used, then the sphere launch reliability is improved, but the device complexity and manufacturing complexity increase
Solution Approach 1:
The patent specifies particular parameter ranges for the elongate reducer (length at least twice the downstream pipe diameter, gradual angle of contact) that optimize both reliability and manufacturability. These parameter changes ensure concentricity alignment while allowing for standard fabrication processes.
3Manufacturing precision
If the reducer length is increased to at least twice the downstream pipe diameter, then the concentricity alignment is improved, but the manufacturing cost and material usage increase
Solution Approach 1:
The patent establishes a minimum length parameter (twice the downstream pipe diameter) that provides sufficient gradual angle of contact for proper concentricity alignment. This parameter change achieves the necessary manufacturing precision while minimizing material usage by providing a clear lower bound rather than requiring excessive length.
Data Source
AI summary
During a water draw test, horizontal type bidirectional sphere provers with a straight calibrated section of pipe between the detector switches sometimes suffer from sphere launch failure which typically results in a failed water draw test. These types of provers, especially in larger pipe diameters will benefit from an elongate concentric fabricated reducer attached to the outlet of each launch tube. These elongate concentric fabricated reducers result in a successful sphere launch on the first attempt. Assuming all the other components of the prover are properly designed and assembled, a successful sphere launch will result in a successful water draw test on the first attempt saving time, money and reputation.