High-Pressure Seal Assembly With Replaceable Erosion Surface
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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 incorporates a housing with intersecting conduits and recessed grooves that transfer erosion wear from the device body to the component sealed with the body, allowing for easier and less expensive repairs by relocating the wear to a less complex and less expensive mating component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the valve body bore is used as the sealing surface, then the sealing integrity can be maintained, but the bore suffers erosion from corrosive and abrasive fluids leading to leakage and cumbersome repairs
Solution Approach 1:
The sealing system is divided into two independent parts: the valve body bore and the insert. The insert is a separate component that can be removed and replaced independently from the valve body. This segmentation allows the sealing function to be maintained while protecting the valve body from direct erosion contact, as the insert absorbs the wear and can be easily replaced without repairing the expensive valve body.
Solution Approach 2:
The insert acts as an intermediary component between the corrosive fluid and the valve body bore. It serves as a sacrificial element that protects the valve body from direct exposure to abrasive and corrosive fluids. The insert can be made from materials highly resistant to specific erosive agents, transferring the erosion damage to a replaceable component rather than the permanent valve body structure.
2Stress or pressure
If the valve body is designed to withstand high pressures, then the device can handle high-pressure flows, but the cost of repairing the body increases due to weld build-up and machining operations
Solution Approach 1:
The valve body is segmented into the permanent pressure-containing structure and the replaceable insert. The valve body is designed to withstand high pressures without needing to be repaired, while the insert handles the sealing function and absorbs erosion damage. This allows the expensive valve body to remain intact and reusable.
Solution Approach 2:
The insert is designed as a disposable or easily replaceable component that absorbs erosion damage. Instead of repairing the expensive valve body through complex weld build-up and machining operations, the inexpensive insert can be quickly removed and replaced. This transforms a complex, costly repair operation into a simple component replacement task.
3Reliability
If the seal in the insert abrades against the bore, then sealing occurs, but erosion of the valve body bore results in leakage in a short amount of time
Solution Approach 1:
The insert is designed as a sacrificial component with a limited service life that absorbs erosion damage. It is made from materials that are highly resistant to specific erosive agents but can eventually wear out. When the insert shows signs of erosion or leakage, it is simply replaced rather than attempting to repair the valve body. This extends the overall operating life of the valve by protecting the permanent body structure.
Solution Approach 2:
The insert is designed to be discarded after a certain period or when erosion occurs, rather than attempting to restore it. The replaceable insert absorbs the wear and tear from abrasive fluids, and when it becomes damaged, it is removed and replaced with a new one. This discarding approach is more economical and time-effective than trying to repair or restore the insert or valve body.
4Loss of time
If repairs are performed in the oilfield, then operational downtime is reduced, but the cumbersome repair process still increases operational costs
Solution Approach 1:
The valve is segmented into a permanent valve body and a replaceable insert assembly. This segmentation allows the insert to be quickly removed and replaced in the field without complex disassembly or specialized repair equipment. The modular design enables field repairs to be performed by simply swapping the insert, dramatically reducing downtime compared to traditional repair methods requiring weld build-up and machining operations.
Solution Approach 2:
The insert is designed as an inexpensive, easily replaceable component that can be swapped out in the field without specialized repair facilities. When erosion or damage occurs, the insert is removed and replaced with a new one, eliminating the need for complex repair operations. This disposable approach transforms a multi-day repair process into a quick component swap, reducing operational downtime and costs.
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.