Electronically Controlled PRV System for Rapid Pressure Relief
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Solution Overview
Problem
Existing pressure relief valve systems in high-pressure fluid injection operations, such as those in well sites, are slow to open and require multiple revolutions, posing risks during lubrication and maintenance, and lack efficient methods for servicing.
Innovation Solution
An electronically controlled pressure relief valve system using plug valves actuated by a rotary actuator, which can open in less than 1.5 seconds and with less than one complete revolution, along with a system controller that monitors pressure and sends actuation signals to relieve excess pressure, and includes a mechanical pop-off valve as a safety feature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If traditional pressure relief valve systems are used, then the system structure is simple, but the valve opening speed is slow and requires multiple revolutions
Solution Approach 1:
The patent replaces traditional mechanical valve actuation mechanisms with an electronically controlled system. The electronically controlled pressure relief valve uses an electronic actuator to open the valve rapidly (in less than 1.5 seconds with less than one complete revolution) when pressure exceeds the threshold, eliminating the slow multiple-revolution opening requirement of traditional mechanical systems.
Solution Approach 2:
The patent introduces a pressure sensor as an intermediary between the pressure source and the valve actuation system. The pressure sensor continuously monitors fluid pressure and sends signals to the electronic actuator, enabling automated rapid response when pressure exceeds the predetermined threshold, thus achieving fast valve opening without direct mechanical linkage.
2Reliability
If traditional pressure relief valve systems are used, then the device complexity is low, but the safety risk during lubrication and maintenance is high
Solution Approach 1:
The patent implements a feedback control system where the pressure sensor continuously monitors fluid pressure and provides real-time feedback to the electronic actuator. This automated feedback mechanism ensures the valve opens rapidly and reliably when pressure exceeds the threshold, significantly improving safety during lubrication and maintenance operations compared to traditional systems.
Solution Approach 2:
The electronically controlled system enables the pressure relief valve to automatically detect and respond to overpressure conditions without human intervention. The pressure sensor and electronic actuator work together to self-regulate the valve opening, improving safety during maintenance by eliminating the need for manual operation in hazardous high-pressure conditions.
3Loss of time
If traditional pressure relief valve systems are used, then the system is easier to manufacture, but the response time to relieve pressure is slow
Solution Approach 1:
The patent replaces traditional mechanical timing mechanisms with an electronically controlled actuation system. The electronic actuator responds immediately when receiving signals from the pressure sensor, achieving rapid pressure relief in less than 1.5 seconds. This electronic substitution eliminates the inherent delays of mechanical systems while the modular design keeps manufacturing complexity manageable.
4Speed
If rapidly opening valves are implemented, then the pressure relief speed is improved, but the difficulty of servicing and maintaining the valve increases
Solution Approach 1:
The patent segments the pressure relief valve system into distinct functional modules: the pressure sensor, the electronic actuator, and the valve body. This modular segmentation allows for easier maintenance and repair of the rapid-opening valve, as each component can be independently serviced or replaced without affecting the entire system, thus reducing the difficulty associated with maintaining high-speed valves.
Data Source
AI summary
A method of servicing a pressure relief valve system for a fluid injection system is provided. The method includes providing a skid, with the skid having a frame that supports a horizontal I-beam overhead. The method also includes providing a pressure relieve valve (“PRV”) system supported by a platform of the skid. The PRV 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. Plug valves may be quickly removed for service using a hoist system supported by the skid.