Erosion Resistant Flow Conduit with Pressure Monitoring
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Solution Overview
Problem
Existing piping systems in gas and oil wells, particularly at bends and changes in direction, suffer from premature failure due to erosion caused by particulates, which is difficult to detect until failure occurs, posing a risk of catastrophic events.
Innovation Solution
A flow directing insert made of erosion-resistant materials, such as ceramics, is housed within a pressure chamber that allows for failure detection by monitoring pressure differentials between the fluid stream and an intermediate fluid pad, enabling early detection and replacement of the insert before failure occurs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If ceramic lined pipes and machined ceramic elbows are used to resist erosion, then erosion resistance is improved, but tensile strength and regulatory compliance deteriorate
Solution Approach 1:
The piping system is divided into two distinct components: an inner ceramic liner that provides erosion resistance and an outer metallic pipe that provides structural strength and pressure containment. This segmentation allows each material to perform its optimal function without compromise.
Solution Approach 2:
The invention uses a composite structure combining ceramic material for the inner liner with metallic material for the outer pipe. This composite approach leverages the superior erosion resistance of ceramics while relying on the metal's tensile strength and regulatory approval for pressure containment.
2Adaptability or versatility
If conventional pressure boundary materials are used, then regulatory compliance is improved, but erosion resistance deteriorates
Solution Approach 1:
The piping system is divided into two distinct components: an inner ceramic liner that provides erosion resistance and an outer metallic pipe that provides structural strength and pressure containment. This segmentation allows each material to perform its optimal function without compromise.
3Device complexity
If erosion detection is delayed until failure, then device complexity is reduced, but reliability deteriorates
Solution Approach 1:
The invention incorporates sensors that continuously monitor the condition of the ceramic liner and provide feedback signals when erosion or damage is detected. This allows for early warning and preventive maintenance before catastrophic failure occurs.
Solution Approach 2:
The detection system is designed to identify erosion and damage in the ceramic liner before it progresses to catastrophic failure. By detecting issues preliminarily, the system enables timely intervention and replacement, preventing unexpected failures.
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 effectively prevents catastrophic failures by detecting insert failure through pressure changes, allowing for timely replacement and minimizing erosion damage, while using unconventional materials within regulatory compliance.
Implementation Method 1
Within the pressure chamber, an intermediate fluid pad is formed about a substantial length of the flow directing insert, between the insert and the housing
Implementation Method 2
failure at any location therealong being detectable by means associated with the housing
Data Source
AI summary
A particulate-accommodating fluid flow directing apparatus comprises a failure detection housing containing a flow directing insert, the housing serving as a pressure boundary; failure at any location along the insert being detectable by means associated with the housing. The insert can be manufactured of erosion resistant materials, including non-ductile materials such as ceramics. The insert is sealed to the housing at an inlet and a discharge forming a pressure chamber between the insert and housing. The pressure chamber can be maintained at a pad pressure complementary to the process pressure, the pad pressure being maintained and monitored for indication of insert failure.