Emergency Flow Restrictor Installation Without Pipeline Shutdown
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Solution Overview
Problem
The current method for installing an Emergency Flow Restrictor Device (EFRD) on pipelines requires shutting down the fluid flow, which is cumbersome, expensive, and poses safety challenges due to the need for extensive preparation and coordination, often taking months and involving significant logistical and environmental concerns.
Innovation Solution
A method involving face plates, a cutting wheel, and a valve body that allows for the installation of an EFRD on a pipeline without stopping the fluid flow, using a cutting tower and drive linkage to sever the pipeline section while maintaining continuous operation, similar to a 'hot tap' procedure but with pre-installed face plates and cutting system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the current method is used to install an EFRD, then the valve can be installed on the pipeline, but the pipeline flow must be stopped for about 24 hours requiring extensive preparation and coordination
Solution Approach 1:
The face plate is divided into two separate halves that can be installed independently on opposite sides of the pipeline. This segmentation allows the cutting wheel and valve body to be installed without requiring a complete pipeline shutdown, as each half can be positioned and welded while the pipeline remains operational on the other side.
Solution Approach 2:
The two face plate halves are installed and welded to the pipeline in advance before the pipeline section needs to be cut. This preliminary installation creates a sealed chamber that can contain the cutting operation and valve installation without affecting pipeline flow, allowing these operations to be performed while the pipeline remains operational.
2Ease of manufacture
If the current method is used to install an EFRD, then the valve can be installed, but extensive preparation work and expense are required including parking areas and wooden mats
Solution Approach 1:
By dividing the face plate into two halves, the installation equipment and materials can be staged on much smaller areas. Each half can be transported and positioned separately, eliminating the need for large parking areas and extensive wooden matting that would be required to support all equipment simultaneously over the pipeline.
Solution Approach 2:
The face plate halves are installed in advance when site access requirements are minimal. This preliminary installation allows the majority of the heavy equipment to be removed from the site before the cutting and valve installation operations, reducing the need for large parking areas and extensive ground protection measures.
3Ease of operation
If the current method is used to install an EFRD, then the valve can be installed, but safety challenges increase due to working crews around the clock under a tight timeline
Solution Approach 1:
The installation process is divided into separate phases that can be performed during different time periods. The face plate installation can be completed during normal business hours, while the cutting and valve installation occur in a controlled manner afterward. This segmentation eliminates the need for around-the-clock crew work and reduces safety risks associated with tight deadlines.
Solution Approach 2:
By installing the face plate halves in advance under normal working conditions, the subsequent cutting and valve installation operations can be performed in a more controlled and safer manner. The preliminary installation establishes a secure framework that allows later operations to proceed without the time pressure that creates safety challenges.
Data Source
AI summary
A method of installing an Emergency Flow Restrictor Device (EFRD) on a pipeline without stopping the flow of fluid through the pipeline includes the steps of: assembling first and second face plates on a pipeline such that the first and second sealing face are in face to face, spaced relation; assembling a cutting device between the first face plate and the second face plate; assembling a valve body that has an access opening on a length of pipeline such that the valve body encloses the first and second face plates and the cutting device; installing an access valve on the access opening; operating the cutting device to sever the pipeline between the first and second sealing faces; retracting the cutting device and severed section of pipeline; and attaching a valve gate member of the EFRD to the access opening.