Electronically Controlled Pressure Relief Valve for Rapid Fluid Injection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing pressure relief valve systems in high-pressure fluid injection operations, such as those used in hydraulic fracturing, rely on slow-acting gate valves, which can lead to equipment failures and safety risks due to their slow cycling and difficulty in maintenance, necessitating a more rapid and efficient pressure relief mechanism.
Innovation Solution
An electronically controlled pressure relief valve system utilizing plug valves actuated by electric and hydraulic power, capable of opening in less than 1.5 seconds with less than one complete revolution, monitored by real-time pressure transducers and a programmable controller to manage pressure thresholds and ensure rapid fluid release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If gate valves are used in pressure relief valve systems, then the system structure is simple and reliable, but the valve cycling is slow and maintenance is difficult
Solution Approach 1:
The patent replaces traditional mechanical gate valve actuation with an electronically controlled system that uses a ball valve with a 90-degree rotation mechanism. The ball valve is actuated by an electric motor or hydraulic actuator, which provides rapid opening and closing action. This substitution of the mechanical gate valve system with an electronically controlled ball valve system achieves faster valve cycling (in seconds rather than minutes) while maintaining system reliability through the simpler ball valve design.
Solution Approach 2:
The patent implements a dynamic pressure monitoring and control system that continuously monitors wellhead pressure and automatically actuates the valve when pressure exceeds predetermined thresholds. The system includes a pressure transducer, programmable controller, and actuator that work together to provide real-time pressure relief control. This dynamic system allows the valve to respond rapidly to changing pressure conditions, achieving fast cycling capability while the programmable controller manages the complexity of the control logic.
2Ease of repair
If gate valves are used in pressure relief valve systems, then the valve structure is straightforward, but maintenance difficulty increases due to slow cycling
Solution Approach 1:
The patent replaces the traditional gate valve with an electronically controlled ball valve system. The ball valve's 90-degree rotation mechanism is actuated by an electric motor or hydraulic actuator, enabling rapid opening and closing actions that significantly reduce the time required for maintenance operations. The electronic control system allows for remote monitoring and actuation, reducing the need for manual intervention and minimizing maintenance downtime. This substitution transforms maintenance from a time-consuming manual gate valve operation to a rapid, easily controllable ball valve system.
3Reliability
If rapid pressure relief is implemented, then equipment safety is improved, but the valve actuation mechanism becomes more complex
Solution Approach 1:
The patent replaces traditional slow-acting mechanical pressure relief valves with an electronically controlled ball valve system that can open and close rapidly in response to pressure changes. The ball valve is actuated by an electric motor or hydraulic actuator controlled by a programmable logic controller (PLC) that continuously monitors wellhead pressure. This substitution achieves rapid pressure relief (within seconds) significantly improving equipment safety, while the modular electronic control system manages the complexity through standardized components and programmable logic rather than complex mechanical linkages.
Solution Approach 2:
The patent implements a closed-loop feedback control system where a pressure transducer continuously monitors wellhead pressure and provides real-time feedback to a programmable controller. When pressure exceeds predetermined thresholds, the controller automatically actuates the ball valve to relieve pressure. This feedback mechanism ensures rapid response to overpressure conditions, maintaining high equipment safety. The feedback system manages complexity by using simple threshold-based control logic and standardized electronic components rather than complex mechanical pressure-sensing mechanisms.
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 system provides rapid pressure relief, enhances safety by reducing the risk of equipment failure and screen-out conditions, and facilitates efficient maintenance through quick valve cycling, improving operational efficiency in high-pressure fluid injection operations.
Implementation Method 1
a pressure transducer configured to sense fluid pressure within the injection system and generate an electrical signal in response to pressure changes
Implementation Method 2
an actuator configured to rotate the valve from its closed state to its open state in response to an actuation signal
Data Source
AI summary
A pressure relief valve system for a fluid injection system is provided. The pressure relief valve system comprises one or more pressure transducers configured to sense fluid pressure within the fluid injection system. The transducers then generate electrical signals representative of fluid pressure readings within the fluid injection system in real time. Signals are received by a controller which compares pressure readings with a stored pressure threshold. An actuation signal is sent upon detecting a signal representative of a pressure that exceeds the stored pressure threshold, causing an electraulically-actuated valve to rotatably move to an open position. A method for providing pressure relief for a fluid injection system is also provided.