Flapper Check Valve Alignment for Wear Reduction in Severe Service
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Solution Overview
Problem
Check valves used in severe services like hydraulic fracturing suffer from failures and reduced service life due to wear and improper installation, leading to operational inefficiencies and increased maintenance costs.
Innovation Solution
The development of enhanced check valve designs that incorporate features such as flapper alignment members and T-bushings to reduce wear, facilitate proper installation, and allow for in-field customization, thereby improving reliability and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If check valves are used in severe services like hydraulic fracturing, then they can handle high-pressure fluid flow, but they suffer from wear and reduced service life
Solution Approach 1:
The patent introduces T-bushings as intermediary components between the flapper and the valve body. These T-bushings act as mediators that reduce direct contact and wear between the flapper and the valve body, thereby extending service life while maintaining high-pressure fluid flow capability
Solution Approach 2:
The patent applies wear-resistant coatings to the flapper and valve seat surfaces before operation. This beforehand cushioning protects the surfaces from wear during high-pressure operation, extending service life while maintaining pressure handling capability
2Reliability
If check valves are used in severe services, then they can prevent backflow, but they suffer from improper installation leading to failures
Solution Approach 1:
The patent incorporates alignment features and positioning elements during manufacturing that guide proper installation before operation. These preliminary design features ensure correct orientation and positioning of the flapper and other components, preventing installation errors that lead to failures
Solution Approach 2:
The patent designs the valve with self-aligning features and intuitive installation structures that guide the installer through proper assembly without requiring specialized knowledge or tools, making correct installation straightforward and reducing installation-related failures
3Device complexity
If traditional check valve designs are used, then they have simple structure, but they lack in-field customization capability
Solution Approach 1:
The patent divides the check valve into modular segments including the flapper, T-bushings, valve seat, and valve body that can be independently replaced or customized. This segmentation maintains overall structural simplicity while enabling in-field customization by allowing individual components to be swapped without replacing the entire valve
Solution Approach 2:
The patent incorporates adjustable elements and configurable components that allow the valve characteristics to be modified in the field. This dynamic capability enables customization for different applications while maintaining a relatively simple base structure
4Productivity
If check valves operate in harsh environments, then they can perform severe service functions, but wear increases reducing operational efficiency
Solution Approach 1:
The patent employs composite material construction combining different materials with complementary properties - such as wear-resistant coatings on metal substrates, or composite sealing surfaces. This allows the valve to maintain severe service functionality while the wear-resistant materials reduce wear and maintain operational efficiency over time
Solution Approach 2:
The T-bushings serve as intermediary components that reduce wear between moving parts during severe service operation. By introducing these intermediary elements, the valve maintains its productivity in harsh environments while reducing wear-induced degradation of operational efficiency
Data Source
AI summary
A check valve includes a housing having an upstream end and a downstream end. The housing includes a throughbore extending from the upstream end to the downstream end, an outer surface extending from the upstream end to the downstream end, and an access port extending from the outer surface to the throughbore. The access port includes an internal annular shoulder and one or more recesses extending into the internal annular shoulder. In addition, the check valve includes a valve seat disposed in the throughbore of the housing. Further, the check valve includes a check valve assembly at least partially disposed in the access port. The check valve assembly includes a flapper extending into the throughbore and configured to pivot relative to the valve seat between an open position spaced apart from the valve seat and a closed position engaging the valve seat. The check valve assembly also includes one or more flapper alignment members pivotally coupled to the flapper, wherein each flapper alignment member is slidingly seated in one of the recesses in the internal annular shoulder of the access port to align the flapper with the valve seat in the throughbore.