Flapper Valve Segmented Body for Erosion Control
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Solution Overview
Problem
Conventional flapper valves in high-pressure fluid transportation systems, such as those used in hydraulic fracturing, suffer from turbulence and erosion due to their design, leading to reduced service life and increased pressure losses, especially when handling abrasive and corrosive fluids.
Innovation Solution
The design of a flapper valve with a removably assembled body, accessible seat, and pivotally mounted flapper, featuring a service port with a cap and filler body, which minimizes turbulence and erosion by allowing easy replacement of components and reducing the enlarged passage area, utilizing hammer unions and threaded connectors for assembly, and incorporating a beveled seat insert and pin-restricted rotation to enhance sealing and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flapper valve design is used, then the valve can handle high-pressure fluid flow, but turbulence and erosion occur leading to reduced service life
Solution Approach 1:
The valve body is divided into multiple segments or sections that can be independently accessed. The passage is segmented to allow direct access to the flapper and seat components without complete disassembly, enabling targeted maintenance and inspection to address erosion and turbulence issues
Solution Approach 2:
The design incorporates preliminary access features such as removable sections or access ports that allow inspection and replacement of eroded components before complete failure occurs. This preliminary access enables proactive maintenance to extend service life
2Ease of repair
If conventional flapper valve design is used, then the valve structure is simple, but maintenance and component replacement are difficult
Solution Approach 1:
The valve body is segmented into accessible sections with removable parts that provide direct access to the flapper and seat. This segmentation allows maintenance personnel to reach internal components without complete disassembly, significantly improving ease of repair while adding only minimal structural complexity
Solution Approach 2:
Access ports or intermediary chambers are introduced as mediator structures that provide a pathway to internal components. These intermediary elements facilitate maintenance access without requiring complete valve disassembly, balancing ease of repair with acceptable structural complexity
3Ease of operation
If enlarged passage area is provided for flapper operation, then the flapper can pivot freely, but pressure losses increase due to turbulence
Solution Approach 1:
The passage cross-section is varied locally along its length. The passage area is enlarged only in the specific region where the flapper pivots to ensure free movement, while maintaining a smaller cross-section in other regions to minimize overall turbulence and pressure losses. This local quality change optimizes both flapper operation and energy efficiency
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 novel flapper valve design extends the service life, reduces turbulence and erosion, and facilitates easier maintenance, ensuring reliable operation in high-pressure applications by minimizing the enlarged passage area and using self-energizing seals to reduce fluid circulation within the cap, thus enhancing the sealing efficiency and reducing operational downtime.
Implementation Method 1
In the open position, the flapper is pivoted away from the seat and allows fluid flow through the valve
Implementation Method 2
In the closed position, the flapper bears on the seat and shuts off back flow through the passage
Data Source
AI summary
Flapper valves may be provided in fluid transportation systems. The flapper valves comprise a body adapted for assembly into the system. The body comprises a first sub and a second sub which are removably assembled to each other. A passage is defined in the body which extends through the first and second subs. A seat is removably mounted in the passage. The seat is accessible by disassembling the first sub and the second sub. The valve also has a service port. A cap removably closes the port. A flapper is removably a mounted within the service port for pivoting movement between a closed position and an open position. In the closed position the flapper shuts off back flow through the passage. In the open position, the flapper allows fluid flow through the valve. The flapper is accessible by removing the cap from the service port.