Pressure Relief Valve With Flushable Ball Actuator
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High-pressure flowline components in fracturing systems are prone to failure due to harsh conditions, leading to reduced effectiveness and increased costs, as existing pressure relief valves are susceptible to wear, damage, and inaccurate pressure regulation.
Innovation Solution
A pressure relief valve system with a flushable ball and linear actuator that opens at a threshold pressure, allowing fluid to divert excess pressure and prevent component failure, featuring a control system for precise operation and minimal disruption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pressure relief valves are used in high-pressure fracturing systems, then pressure relief function is provided, but the valves are susceptible to wear, damage, and inaccurate pressure regulation
Solution Approach 1:
The patent employs a disposable burst disc as the pressure relief mechanism instead of a reusable valve. The burst disc is designed to fail at a predetermined pressure, providing reliable pressure relief without being susceptible to wear or damage from repeated operation. After bursting, the disc is replaced with a new one, ensuring consistent performance without degradation over time.
Solution Approach 2:
The patent extracts the pressure-sensing and actuation function from the pressure relief component itself. A separate pressure sensor detects system pressure and actuates the burst disc through a hydraulic or pneumatic system, allowing the burst disc to focus solely on pressure relief without being affected by control mechanism wear.
2Reliability
If pressure relief valves are installed to prevent component failure, then system safety is improved, but operational interruptions and replacement frequency increase
Solution Approach 1:
The burst disc is pre-calibrated to burst at a specific pressure threshold before any damage can occur to flowline components. This preliminary pressure relief action prevents catastrophic failures and extends operational life of expensive components, reducing both safety incidents and replacement frequency.
Solution Approach 2:
By using an inexpensive disposable burst disc instead of a complex reusable valve, the system achieves reliable pressure protection with minimal maintenance. The burst disc is replaced quickly after failure, causing minimal operational interruption compared to repairing or replacing expensive flowline components.
3Measurement precision
If automatic pressure control systems are implemented, then pressure regulation accuracy is improved, but system complexity increases
Solution Approach 1:
The patent replaces complex mechanical pressure relief valves with a simpler system combining an electronic pressure sensor and a predetermined-pressure burst disc. The sensor provides accurate digital pressure measurement, and the burst disc provides precise mechanical pressure relief at a predetermined threshold, eliminating the need for complex mechanical adjustment mechanisms.
Solution Approach 2:
A hydraulic or pneumatic intermediary system connects the electronic pressure sensor to the burst disc actuation mechanism. This intermediary translates electronic pressure signals into mechanical actuation force, allowing accurate pressure control without direct mechanical linkage between the sensor and relief mechanism.
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 system effectively relieves excess pressure without restricting flow, enhancing the reliability and longevity of high-pressure flowlines, reducing the need for frequent component replacement and operational interruptions.
Implementation Method 1
The linear actuator is mounted for linear movement in response to detection of the threshold pressure from a normally extended position to a retracted position
Implementation Method 2
In the retracted position the ball can be flushed out of the valve by fluid flowing through the passage, thereby opening the valve
Implementation Method 3
The ball is adapted to engage the valve seat to block flow through the passage
Data Source
AI summary
Pressure relief valves may be tapped into high-pressure flow lines. The pressure relief valve is normally shut and is adapted to open at a threshold fluid pressure. It comprises a body, a passage, a valve seat, a ball, and a linear actuator. The passage is defined in the body and has a valve inlet and a valve outlet. The valve seat is in the passage. The ball is adapted to engage the valve seat to block flow through the passage. The linear actuator is mounted for linear movement in response to detection of the threshold pressure a from a normally extended position to a retracted position. In the extended position the ball engages the valve seat to close the passage, thereby shutting the valve. In the retracted position the ball can be flushed out of the valve by fluid flowing through the passage, thereby opening the valve.