Bi-Directional High-Pressure Plug Sealing Against Debris Wear
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Solution Overview
Problem
High pressure valves relying solely on metal-to-metal sealing mechanisms are unreliable due to changing tolerances, environmental impacts, and debris, which compromise the sealing ability over time.
Innovation Solution
A high-pressure plug design featuring bi-directional floating ball valves with sealing grooves that form a secondary seal using pressurized grease, allowing for a metal-to-metal seal against fixed inserts within a valve body, and utilizing hydraulic and pressurized grease forces to maintain a secure seal during fracturing operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a metal-to-metal sealing mechanism is used in high pressure valves, then the valve can operate at high pressures, but the sealing reliability deteriorates over time due to changing tolerances, environmental impacts, and debris
Solution Approach 1:
The patent introduces a grease as an intermediary substance between the metal sealing surfaces. The grease is delivered through a flow path that directs it onto the sealing surfaces, creating a protective film that mediates between the metal surfaces and the harsh environment, preventing direct metal-to-metal contact and reducing wear while maintaining sealing capability
Solution Approach 2:
The system performs preliminary action by proactively delivering grease to the sealing surfaces before damage occurs. The grease delivery mechanism is designed to continuously or periodically apply lubrication and protection to the sealing surfaces in advance, preventing debris accumulation and wear rather than addressing problems after they arise
2Adaptability or versatility
If a floating barrier design is used to allow bi-directional sealing, then the valve can seal in both directions, but the barrier becomes vulnerable to upstream forces that cause movement and exposure to sand and chemicals
Solution Approach 1:
The grease serves as a protective intermediary between the floating barrier and the harmful environment (sand and chemicals). By continuously supplying grease to the sealing surfaces of the floating barrier, the system creates a protective barrier that shields the metal surfaces from direct contact with abrasive sand and corrosive chemicals, while still allowing the barrier to float and seal bi-directionally
3Reliability
If sealing grooves are added to receive pressurized grease for secondary sealing, then sealing durability is enhanced, but the device complexity increases
Solution Approach 1:
The grease flow path system is designed to serve multiple functions: it delivers lubrication to reduce friction, provides a secondary sealing mechanism to enhance sealing reliability, and protects the sealing surfaces from environmental damage. By combining these functions into a single grease delivery system, the patent avoids the need for separate mechanisms for each function, thereby limiting the increase in complexity
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
Enhances sealing durability, operational efficiency, and reduces maintenance costs by creating a self-sustaining metal-to-metal seal with a secondary grease seal, protecting against debris and chemicals, and extending the lifespan of the valve components.
Implementation Method 1
sealing grooves positioned on sealing surfaces of the plug are configured to receive pressurized fluids to form a secondary seal
Implementation Method 2
utilize pressure from fracturing, wirelines, etc. to set a metal to metal seal against a fixed insert within a valve body
Data Source
AI summary
A bi-directional floating plug that utilizes pressure from fracturing, wirelines, etc. to set a metal-to-metal seal against a fixed insert within a valve body, and a secondary seal via a energized fluid within a sealing groove while the metal-to metal seal is retained.