Blow Case Gravity-Open Clapper Valve Debris Transfer
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Solution Overview
Problem
Existing blow cases for waste streams in well systems face issues with debris accumulation and maintenance due to failure points in the design, such as trash getting caught in check valves and air valves failing from debris and wear, leading to reduced capacity, over-cycling, and costly maintenance.
Innovation Solution
An improved blow case design featuring a top-mounted pneumatic valve, clapper valve, and access port for flushing and clearing, using compressed gas to force liquid and debris through an outlet pipe, with a containment wall and internal storage compartment to prevent debris collection, and a gravity-open valve for reduced maintenance needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the inlet pipe terminates directly above the outlet pipe with an internal extension, then debris is directly transferred from inlet to outlet preventing collection in the blow case body, but the pipe configuration becomes more complex
Solution Approach 1:
The inlet pipe is segmented into multiple sections: an external portion, an internal extension portion that terminates above the outlet pipe, and a discharge end. This segmentation allows debris to be directed through specific pipe sections rather than accumulating in the blow case body, resolving the contradiction by creating a dedicated debris transfer path.
Solution Approach 2:
The internal extension of the inlet pipe acts as an intermediary structure that bridges the inlet and outlet areas. By extending the inlet pipe internally to terminate directly above the outlet pipe, it creates a direct debris transfer corridor that prevents debris collection in the blow case body while maintaining system reliability.
2Use of energy by moving object
If a gravity-open clapper valve is used instead of a traditional check valve, then gas pressure requirements are reduced and maintenance is simplified, but the valve structure becomes more complex
Solution Approach 1:
The clapper valve incorporates a gravity extension arm that extends outward to shift the center of gravity, creating a gravity-open mechanism. This counterbalances the need for gas pressure to open the valve, allowing it to open automatically when pressure is applied and close when pressure is released, thereby reducing continuous gas pressure requirements while managing the increased structural complexity.
Solution Approach 2:
The clapper valve is designed as a dynamic component that rotates on a hinge pin between open and closed positions. The gravity extension arm creates a dynamic balance where the valve opens with gas pressure and closes under gravity, eliminating the need for continuous pressure maintenance and reducing overall gas pressure requirements despite the more complex valve structure.
3Ease of repair
If the float valve is mounted on top of the blow case body with above-ground components, then maintenance and servicing are simplified with easy access, but the valve is exposed to environmental factors
Solution Approach 1:
The float valve is repositioned from a traditional below-ground or internal mounting to a top-mounted configuration with above-ground components. The float arm extends through the float aperture into the blow case while the float body and valve body remain accessible from above ground, creating a multi-dimensional arrangement that provides easy maintenance access while managing environmental exposure through strategic component placement.
Solution Approach 2:
The float aperture serves as an intermediary opening that allows the float arm to extend into the blow case interior while the float body remains outside. This intermediate structure enables the valve to be serviced from above ground without requiring excavation or disassembly, simplifying maintenance access while the float arm protects the internal mechanism from direct environmental exposure.
4Productivity
If compressed gas is used to force liquid and debris through the outlet pipe, then debris removal is improved, but gas pressure requirements increase
Solution Approach 1:
The system extracts and removes debris directly from the blow case body through the outlet pipe using compressed gas. The internal extension of the inlet pipe and the outlet pipe configuration work together to extract debris through a direct path, improving removal efficiency while the clapper valve and gravity-open mechanism help manage pressure requirements by allowing gravity-assisted flow.
Solution Approach 2:
Compressed gas is used to force liquid and debris through the outlet pipe, utilizing pneumatic pressure to achieve efficient debris removal. The pneumatic action is complemented by the gravity-open clapper valve mechanism that reduces continuous pressure requirements, allowing gas pressure to be applied intermittently only when debris removal is needed, thereby improving productivity while managing pressure stress.
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 minimizes downtime by directly transferring debris from the inlet to the outlet, reducing the need for constant gas pressure, allowing for easy above-ground servicing, and enabling efficient flushing and clearing of the blow case, thereby reducing maintenance costs and improving system reliability.
Implementation Method 1
a float body (158) connected to the float arm. The float valve (150) controls a gas pressure supply directed through a nozzle against the back face of the clapper
Implementation Method 2
The clap assembly (210) includes a gravity extension arm (214) connected to the hinge pin (212) which uses gravity to naturally open the valve
Implementation Method 3
using compressed gas to force liquid and debris through an outlet pipe
Data Source
AI summary
A blow case with an inlet pipe positioned to gravity direct debris to an outlet pipe. The inlet pipe having a discharge end sealed by gravity open clapper style check valve that is closed by activation of pneumatic pressure through a float style pneumatic valve. The check valve has a top mounted access port and aperture allowing for direct above ground servicing access to both the clapper inside the valve and has a removable clapper and access port for servicing the outlet pipe. The float style pneumatic valve is also top mounted for ease of service and removal and is remotely positioned from the outlet pipe to allow for removal of the valve for flushing of the debris from the blow case.