High-Pressure Flow Seal Assembly With Replaceable Erosion Insert
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Solution Overview
Problem
High-pressure flow devices in the oil and gas industry, such as valves and fluid ends, face erosion issues due to corrosive and abrasive fluids, leading to leakage and cumbersome repairs, which increase downtime and operational costs.
Innovation Solution
The design involves a fluid end assembly with a housing and conduits that intersect, featuring recesses and grooves for mounting seals, which transfer erosion wear from the body to less complex and less expensive components, such as inserts and retaining nuts, reducing the complexity and cost of repairs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If seals are mounted in the valve body bore to seal against the insert, then sealing integrity is achieved, but erosion of the valve body bore occurs leading to leakage
Solution Approach 1:
A seal carrier insert is introduced as an intermediary component between the valve body bore and the seal. The seal carrier insert absorbs the erosion from abrasive fluids, protecting the valve body bore while maintaining sealing integrity. The seal is mounted in the seal carrier insert rather than directly in the valve body bore, transferring the harmful erosion effect to the replaceable seal carrier insert.
Solution Approach 2:
The seal carrier insert is designed as a sacrificial, replaceable component that absorbs erosion damage. Instead of repairing the expensive valve body, the seal carrier insert can be easily replaced when eroded, reducing maintenance costs and downtime. This disposable approach protects the permanent valve body structure.
2Reliability
If the valve body is repaired through weld build-up and machining, then leakage is fixed, but the repair process is cumbersome and causes downtime
Solution Approach 1:
The sealing system is segmented into separate functional components: the permanent valve body, the replaceable seal carrier insert, and the seal. This segmentation allows the seal carrier insert to be independently replaced without affecting the valve body structure, enabling quick field repairs without cumbersome welding and machining operations.
Solution Approach 2:
The seal carrier insert is designed as a replaceable component that can be quickly swapped out when eroded or damaged. This eliminates the need for time-consuming weld build-up and machining repairs of the valve body, significantly reducing downtime and allowing rapid restoration of sealing integrity.
3Reliability
If seals are mounted extending from the insert to seal against the valve body bore, then sealing is achieved, but erosion of the valve body bore results in frequent leakage
Solution Approach 1:
The seal carrier insert serves as a mediator that positions and supports the seal while absorbing erosion damage. The seal is mounted in the seal carrier insert which extends into the valve body bore, creating a protective barrier that shields the valve body from direct contact with abrasive fluids and the seal rubbing action.
Solution Approach 2:
The seal carrier insert is designed as a sacrificial component with a limited service life. When it becomes eroded or damaged, it is replaced rather than repaired, protecting the permanent valve body from erosion. This extends the operational life of the valve body while maintaining effective sealing throughout the system's service life.
Data Source
AI summary
Apparatus and method contemplating a high pressure fluid end assembly having a body defining a body bore and defining a recess in the body intersecting the body bore. A closure is joined to the body and forms a sealing surface. A seal is mounted to the body in the recess and configured to extend from the recess beyond the body bore to seal against the sealing surface formed by the closure.